Blinded by lights as he stood in front of cameramen, producers and trainers, the then 155kg teen was asked to remove his singlet and reveal his body to the world.
“It was one of the hardest things I’ve ever had to do,” reveals Sam, recalling his time as a contestant on The Biggest Loser in 2008.
Despite losing an incredible 71kg on the reality weight-loss show he never stopped seeing an overweight and unattractive bloke when he looked in the mirror.
“I used to dread the weigh-ins,” he confesses. “It was extremely confronting. Everyone was looking at me and I was so self-conscious. I had never taken my shirt off in front of anyone before, and there I was standing in just my shorts.”
Now, the “chubby kid” from Campbelltown, NSW, is 27 and has finally laid his demons to rest after reinventing himself – with the help of stunning blonde Natalie Pagett, who had no idea who he was when they fell head over heels for one another in the weights room at his local gym.
“I tried not to think much of relationships,” says Sam, who’s only ever had one other serious girlfriend. “I’d figured I wasn’t ever going to be lucky in that department and basically wrote it off.”
Now, talking about his blossoming romance with Nat and the moment Cupid’s arrow struck, the firefighter can’t stop smiling.
“I always thought Nat had a lovely smile, but I’m not very confident approaching girls,” he says.
“When I first saw Sam, he was a bit shy. I loved that he was into fitness, and he was quite cute, too,” adds Nat, 25.
After a few flirtatious waves across the weights room, it was Nat who conjured up the courage to make the first move.
She actually took me out on our first date – to speedway car racing!” laughs Sam.
Flashing their toned beach bods, the loved-up Sydney couple are now the picture of health and happiness, even if they do “fight” over who’s fitter.
“I just want to have bigger muscles than him,” jokes Nat.
“She’s close,” Sam deadpans.
Read all about Sam and Nat’s romantic courtship tale only in Woman’s Day, on sale 4th May.