MEETING Allan Robinson at his Newcastle home, it's clear that he's no wallflower. The garish stripes of his knitted cardigan announce his presence from afar and in his living room are various props, among them a giant case labelled Clogs the Clown.

For 20 years, 61-year-old Allan has played this role, delighting audiences throughout the region. It was through clowning that he first got involved in ballet. "A number of years ago I joined Equity and when Birmingham Royal Ballet come up to the North-East, they contact the Equity local secretary to ask about extras," he says. "They've got certain criteria that you have to meet in terms of size and weight. The first time I was asked to take part was about four years ago."

Yet the spotlight is a far cry from Allan's former life. A mechanic by trade, he spent the bulk of his career as a transport manager. Although he worked in the macho world of grease and engines, from an early age, he'd harboured ambitions to perform. "When I was about eight I used to go down to Newcastle Quayside on a Sunday morning and watch a chap selling magic tricks, and from that I started doing little shows for family and friends," says Allan. "I probably stopped doing it as much when I was about 16 or 17."

As his father owned a garage, much of his childhood was spent around cars. When he left school, it seemed natural that he should continue this. "I think it was always expected that I was going to go into the motor trade," says Allan. "I started an apprenticeship as a motor mechanic, and I was there until I was 21."

For the next few years he did various jobs, including selling and teaching a course on car maintenance. He then went into fleet management, initially working for the Gateshead-based department store Shepherd's, before becoming a transport manager for the plant hire firm SLD Pumps. It was when the occupation he'd once loved began to turn sour that Allan took up clowning. "I used to use up all my holidays and weekends doing it," he says. "Because I had such a dreadful weekday job it was a great release."

Yet, far from planning to become a clown, he stumbled into it by chance. His first step was taking up juggling. "I was at the Fish Quay Festival in North Shields when I met some student jugglers, and I started learning to juggle," he says. "Bearing in mind that I was in my 40s, it was a bit difficult. Then I went stilt walking and unicycling and things like that."

Allan's debut as a clown came through a friend. He recalls it was a sheer fluke. "A friend of mine who was in the Magic Circle and an ex-policeman became a clown himself," he says. "He was known as Coppo the Clown. He'd seen me enter some competitions in the Magic Circle and decided I would make a good clown. He rang me one day and said, 'I've got a booking and I need someone else to come along with me'. I had no idea of what to do - I didn't even know how to put make-up on. He said, 'Don't worry, I'll give you an outfit and drop some make-up off at your office. Have a play around with it'."

But the clothes and make-up failed to materialise - leaving Allan to arrive at the venue completely unprepared. "It was an outdoor event at Newburn riverside," he recalls. "I got there bright and early and Max (the ex-policeman) arrived with a few minutes to go and said, 'Just get your gear and follow me. You'll be all right'. And I was. The next day, people rang me and said, 'I believe you're now Clogs the Clown'."

Over the years, Allan has performed just about everywhere, including at schools, castles, and even once at Durham Prison. "It was quite an experience," he says wryly. Yet until four years ago, his CV had never stretched to ballet. "I'd never even seen a ballet," he says. I'd never met a dancer before and I had no idea about it."

When he was offered extra work with Birmingham Royal Ballet, however, he was keen to have a go. He admits he didn't know what he was getting into. "I didn't realise I would have to wear ballet shoes and tights and things like that," says Allan. "It was a bit weird at first, but since then I've started doing Jasper the Jester, and he wears tights, so I've got used to it."

His inaugural show was Romeo and Juliet, in which he has now appeared twice. This week's performance of Sleeping Beauty, at the Sunderland Empire, marks his third outing with Birmingham Royal Ballet. Allan has fond memories of his introduction to the world of dance.

"We did the costume fitting and a small rehearsal on the Monday night then, on the Tuesday, we did a dress rehearsal in the afternoon and the evening performance," he says. "It was brilliant. Every night, I used to stand in the wings just watching the dancers. The one thing that surprised me was the number of girls who smoke, but they are really fit. They're exercising all the time - stretching their limbs and warming up. It's really fascinating. It's not just the dancing, it's the expressions and everything. The fight scenes are really quite impressive."

As an extra, Allan never knows which part he'll play until the rehearsal. So far, he's been a beggar, a litter carrier and a monk. "You're part of the ballet as an actor and you have various costumes," he says. "Someone is there to help you change clothes and the props are ready just to take on. The whole organisation is fantastic."

While his wife Val and children Ian and Carole have yet to see him on stage, they're all supportive of what he does. He says that now he's got a taste for ballet, he'd love to do more. "If I was asked to, I certainly would because it's tremendous," says Allan. "A lot of people drink or do drugs but if you've got an audience in front of you and they're with you and it's going really well, there's nothing like it."

* Sleeping Beauty runs at the Sunderland Empire from tomorrow to Saturday.

* Allan can be booked as Clogs the Clown by ringing 0191-281 0799 or 07989 801906