Knight rider

Yet the Welsh-born star says it's his latest movie, a relatively low-budget affair called The World's Fastest Indian, which has brought him the biggest joy of his acting career so far.

"It really was the best film experience I've ever had," he says enthusiastically. "It was so enjoyable because it was such an outdoor, open-air movie and I play a character with a sunny disposition. I liked his philosophy of life."

In the film, the actor stars as New Zealander Burt Munro, who at the age of 68 risked everything to take his classic 1920 Indian motorcycle to the Bonneville Salt Flats in Utah, in an attempt to break the world speed record in 1967.

Although he relished the role, it did leave him a little saddle sore.

"I haven't been on a motorbike in years. The last time was when I did National Service, in the army," he explains, grimacing. "So when I got on this one I had to go back to basics, like how to get on it and how to start it. It was really uncomfortable.

"I wore some padding underneath my stomach because I was lying flat on it. But Burt Munro didn't have anything like that. He rode it with no protection at all. But it was great fun being on a motorbike."

The 68-year-old, who made his big screen debut four decades ago alongside Katharine Hepburn in The Lion In Winter and has gone on to appear in almost 100 films, says he'd never come across a character like Burt Munro.

"I instantly wanted to play him, because he had tremendous courage. I think he was scared but just thought, 'To hell with it, we're going to die one day, so I might as well take my chances'," he explains.

"I think that spirit is just great. To overcome fear is the greatest virtuous courage and I think Burt's whole philosophy of life was to live it to the full."

And he not only had to overcome anxieties about riding a motorbike, he also faced another daunting challenge - mastering the New Zealand accent.

"Burt was from Invercargill and had a Southland accent, which actually sounded a little Irish or Cornish, so it was easier than I expected," says the Port Talbot-born actor.

"I watched documentary footage of Burt and got the patterns of his voice. The trick is not to get too fanatical about getting the accent too accurate, because then that becomes a mask."

Getting under the skin of such a vibrant and daring man gave the star a renewed vigour for acting. He's made no secret of the fact he hasn't always enjoyed his profession in the past. He battled a serious alcohol problem in his 20s but has rarely been out of work.

In 1991 he proved he was still at the top of his game with his Oscar-winning performance in The Silence Of The Lambs - a film he now looks back on as life-changing.

"That film put me in a new category I guess," he reflects. "From then on I have enjoyed more doing what I do. I loved The Remains Of The Day, Shadowlands and Nixon, which all came along afterwards."

A decade after his portrayal as murderous cannibal Dr Hannibal Lecter in The Silence Of The Lambs, he reprised the role with the box office smash hit sequel, Hannibal. But now the star insists there'll be no more psychopaths.

"I've had a good time playing weird guys and all the others," he says with a laugh. "But after a while you really do want to get away from that type."

Instead he's concentrating on a run of new movies which more than prove his versatility. He recently appeared alongside Gwyneth Paltrow in the drama Proof and will next be seen in All The King's Men with Sean Penn, and Beowulf, which also stars Ray Winstone.

"He's a great guy," he says of fellow Brit Ray. "I've also just finished a movie about Bobby Kennedy. I'm playing John Casey, a real character who was the doorman at the Ambassador. He retired quite wealthy because of the tips he got from people."

But despite being more in demand than ever, and despite the fact he's playing a complete speed freak in The World's Fastest Indian, these days the actor enjoys a more gentler pace.

Three years ago he married his third wife Stella and now, after a tumultuous private life, seems to finally have found the personal fulfilment he craved. The couple live in Malibu and the star says he likes nothing more than hanging out at the beach.

"I'm a beach bum at heart," he laughs. "I love the life I have. I love the open air. And the funny thing is that by relaxing and taking life more easy I enjoy what I do."

No chance we'll see him bombing down the highway on a Harley then?

"I'm a careful driver," he says shaking his head. "Burt Munro loved the thrill of speed, but I don't. I used to when I was younger, but now, I like to live." Eileen Condon