Richard Karn, the man who spent a decade playing the flannel-clad, steady-handed Al Borland on Home Improvement, recently dropped a significant amount of weight. He lost about 14 kg—or 30 pounds, for those of us still measuring in the imperial system. It’s a transformation that caught a lot of people off guard. When you see a guy in your living room for years looking a certain way, any change feels personal.
Honestly, he looks different. Really different.
The weight loss journey wasn’t just about hitting a number on a scale. It was about a total realignment of his relationship with food and his body. At 69 years old, Karn decided he didn’t want to carry around the extra weight he'd gradually accumulated since his days on the set of Tool Time.
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The "Off-Switch" That Changed Everything
Karn admits that during his years in the spotlight, especially on the Home Improvement set, food was everywhere. Craft services. Events. Banquets. It's easy to lose track of what you're eating when there is a literal buffet of options every single day. He eventually realized he was about 10 pounds over where he wanted to be, and then some.
To fix it, he and his wife of 40 years, Tudi Roche, decided to do it together.
The core of his strategy was a strict six-week "realignment." It wasn't fancy. It wasn't a weird celebrity fad involving charcoal or air.
- The 4-Ounce Rule: He stuck to four ounces of meat and four ounces of vegetables.
- Carb Reduction: He cut out most carbs, at least for the initial phase.
- Portion Control: This was the heavy lifter.
Karn says this process helped him find his "off-switch." You know that feeling when you're eating pizza and you realize you're full, but you eat the rest of the pie anyway because it's there? He stopped doing that. He found that two or three slices were actually enough. He didn't need the whole thing. It’s a simple concept, but incredibly hard to execute when you’ve spent decades doing the opposite.
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Why He Thought He Looked "Too Thin"
Interestingly, Karn faced a problem most of us wish we had. After losing the initial 30 pounds (14 kg), he looked in the mirror and felt he’d gone too far. Even though his doctor was thrilled with the progress, Karn felt he looked a bit gaunt.
"I almost felt like I looked too thin," he shared in a recent interview.
Weight loss at nearly 70 is different than at 25. The skin sits differently. The face loses volume. Karn eventually allowed a few pounds back on, finding a middle ground where he felt healthy without looking fragile. It’s a nuanced take on fitness that you don’t often hear from Hollywood—the idea that "as skinny as possible" isn't always the goal.
The Pilates Factor
If you were expecting Richard Karn to be hitting the bench press like a bodybuilder, you’d be wrong. His secret weapon? Pilates.
He’s been very vocal about how pilates has helped his core and flexibility. It's a low-impact way to keep the body moving without wrecking the joints. He also added some light weightlifting and toning exercises to the mix to keep muscle mass up.
He’s joked about the soreness, though. He’s the first to admit that the first day of a new routine feels fine, but it’s the second and third days that really get you.
Maintaining the Weight in 2026
Maintaining a weight loss of 14 kg isn't a "one and done" situation. It's a constant effort. Karn has mentioned that he still slips up. He still craves things. But the difference now is the awareness.
He avoids eating after 6:00 PM or 7:00 PM. He tries not to let himself get "starving" because that leads to overeating. Most importantly, he and Tudi keep each other accountable. When they are both "on it," there is less junk in the house, which makes the whole thing a lot easier.
Actionable Takeaways from Richard Karn’s Journey
If you're looking to make a similar change, here is what we can learn from Al Borland himself:
- Find a Partner: Doing it with a spouse or friend makes the kitchen environment much easier to control.
- Focus on the "Off-Switch": Practice stopping when you are full, not when the plate is empty.
- Portion the Proteins: Keep meat and veg in balance (around 4 ounces each is a solid starting point for many).
- Listen to Your Doctor, But Also Your Mirror: Find the weight where you feel strong and healthy, not just the lowest possible number.
- Move for Longevity: Choose exercises like Pilates that support your joints and core strength as you age.
Richard Karn’s transformation is a reminder that you can "realign" your health at any age. It doesn't require a magic pill—just a bit of discipline and a willing partner.