Ken Olin’s brief appearance as Holly’s lover David Caplan on Brothers & Sisters last season was no flash in the pan. The veteran TV actor and director, who is also one of the ABC drama’s executive producers, will resurface sometime after the sixth episode of the season, when David resumes his relationship with Holly (played by real-life wife and former thirtysomething costar Patricia Wettig) and works to mend fences with their daughter Rebecca (Emily Van Camp).

But his sudden return will only be half the surprise: Olin has dropped 35 pounds since he was last in front of the camera. “When Holly saw David for the first time last season, he made some comment that he’s not looking that great,” recalls Wettig, who credits a regimen of acupuncture and herbs for her husband’s dramatic weight loss. “Now he’ll get to say, `Yeah, I’m looking good!’”