In 1995, Mellor joined the cast of the soap opera 'Hollyoaks,' in which he played the role of James 'Jambo' Bolton until 1998. He then released a cover version of Leo Sayer's "When I Need You" as a single, which reached number 5 in the UK Singles Chart, as well as a follow-up single called "No Matter What I Do", which reached number 23. He also made an appearance in the music video for Boyzone's Comic Relief single "When The Going Gets Tough". Shortly after, he returned to acting, playing Greg in Is Harry on the Boat?. He played Jack Vincent in Casualty between 2001 and 2003 and has starred as Gaz Wilkinson in the comedy Two Pints of Lager and a Packet of Crisps since 2001. He also made a brief cameo reappearance in a Christmas edition of Hollyoaks, in which he played the ghost of Jambo (although the character is not dead). Mellor also stars as "Barmpot" in the postal worker drama Sorted and has played DC Jed Griffiths in the second series of Murder Investigation Team. Will Mellor first joined the Bullrun family in 2005 when he and teammate, Jeremy Edwards, drove a black BMW M6, competing against four other celebrity teams for a British television series. Will Mellor beat out all the other teams, placing first in the show. He returned in 2006, driving an inconspicuous Audi Q7, hoping to fly under the radar.