Spud began working for Frontier Wrestling Alliance in 2004, and was brought up into the main roster to be used as a jobber for a short time, competing against many larger opponents. During the start of 2005, however, FWA began showcasing their flyweight division; later that year, Spud entered into a tournament to crown a Flyweight Champion. He made it to the tournament final, where he was defeated by Ross Jordan, who became the first FWA Flyweight Champion. However, Jordan was only awarded the match after the referee stopped the contest due to a kayfabe injury to Spud's leg. The pair continued to feud for over 14 months, with Jordan repeatedly attacking Spud in attempts to re-injure his leg. The feud ended when Spud defeated Jordan in a Last Man Standing match at "FWA Last Fight at the Prom" on 30 September 2006.