Ken Curtis appeared on Gunsmoke as a totally different character on at least one episode before creating Festus. The first time I saw that show and recognized Curtis was just recently. He was actually a decent looking man when he wasn’t playing Festus. Festus was really my all time favorite character on Gunsmoke, followed by Doc Adams.
Ken Curtis was an amazing singer. Better than most of those who were far better known.
http://www.youtube.com/watch?v=v517yhi3yms
I saw that episode too recently. He wore suits and acted as a skirt chasing, heart breaking womanizer. I also saw him in a Wagon Train episode recently where he played an Indian trained in the white man's ways.