McHugh played running back and linebacker from 1996-1999 at Chagrin Falls High School in Chagrin Falls, Ohio, where he was a four-year letterman. Upon his graduation in 2000, McHugh had set single season and career rushing records that still stand at Chagrin Falls. He also lettered in wrestling his freshman and sophomore years.
College career
McHugh was a four-year letterman at Penn State from 20002003, starting at fullback his junior and senior seasons. During his career, McHugh ran 82 times for 322 yards and 6 touchdowns. He also made 44 catches for 297 yards and one touchdown.
The next season, McHugh signed a free agent contract with the Detroit Lions. He saw action in 3 games that season. The Lions allocated him to the Frankfurt Galaxy for NFL Europa's 2006 season. He would play in Frankfurt's World Bowl XIV victory over the Amsterdam Admirals. McHugh returned to Detroit for the 2006 NFL season. He was momentarily elevated to the #1 tight end slot due to a wrist injury to Casey FitzSimmons in the preseason, but found himself on the team's practice squad at the start of the season. A week 7 injury to fullback Cory Schlesinger moved McHugh back onto the active roster as a fullback on October 22, 2006. McHugh saw action at fullback on that week versus the New York Jets. His first career reception came against the Atlanta Falcons on November 5, 2006 for seven yards. He would appear in 6 games in 2006, starting 3, and finishing with 3 receptions for 25 yards. McHugh saw increased playing time in 2007, mostly back at tight end. He played in 15 games and finished the season with 252 yards on 17 receptions. He was released by the Lions on August 31, 2008 at the end of training camp.
Pittsburgh Steelers
McHugh signed with the Pittsburgh Steelers on September 3, 2008. He would dress for the Steelers' week 2 game versus Cleveland. An ankle injury to Carey Davis prompted McHugh's move to fullback, where he would be the starter for the Steelers' week 7 game versus Cincinnati. He would be used primarily as a fullback for the remainder of the season and throughout the playoffs, making 3 receptions, totaling 24 yards. In his first season at Pittsburgh, McHugh won the AFC Championship and ultimately Super Bowl XLIII, earning McHugh his first Super Bowl ring. During the two-week period leading up to the Super Bowl, McHugh gained notoriety for having been cut by the Lions, deemed not good enough to play on a team that ultimately went 0-16 for the season, but good enough to play on a Super Bowl team such as Pittsburgh and make major contributions as a blocker for Willie Parker and Ben Roethlisberger.
