"You would find you would have your big emotional scene at 5.48 in the morning, six minutes before sun up."
The best thing which came out of the show, he says, was meeting his now wife, Alyson Hannigan, who played Willow.
Love at first sight? "We have different stories," he laughs. "My side of the case is that I liked her straight off but was hesitant about working and having a relationship at the same time. I was a slow starter on the romantic side of things, so we were just friends for about a year before we started going out. She would say I was flirting ruthlessly the whole time."
He is delighted to be back in the theatre, something he has not done for some time. He is playing Chris, one of the sons of All My Sons, returned from the war a changed man.
He has a father Joe, played by Michael Byrne, suspected of dodgy dealings in the war and a girl played by Alice Patten who was once the girlfriend of a brother presumed to have been killed in action.
"It is an amazing play, one of the great dramas which still speaks to us in our own time, he says. "It addresses dilemmas both moral and political with which Britain, America and the West are still struggling. At its heart, however, is the story of a family and we all have a family."
Today, home remains Los Angeles but he can't quite shake off his Englishness. He was in Germany for the World Cup supporting - England. "I went to all the games apart from the one against Sweden.
It was heart-breaking to see them go out on penalties again."
Even at home in Los Angeles, he subscribes to a Premiership channel. So is he a Liverpool fan?
"Do I have to say red or blue?" he asks. "Just say the American flag is red, white and blue!"
* ALL My Sons opens at the Liverpool Playhouse on September 15 and runs until October 7.
