I love putting roster projections together for more than one reason. But one of the biggest ones is that I start to realize where potential surprises could happen. Recently, I put together my latest prediction for the Dallas Cowboys and I already have some names in mind. 

From veterans in their last chance to make an impact to undrafted rookies vying for a spot on the team, I listed five players who could ruin everyone's projections by shocking us by making the team.

Let's dive in. 

RB Deuce Vaughn

It’s easy to count out the 5-foot-6 running back and not just because of his size. This will be Year 3 of his NFL career and the truth is he hasn’t played much. This offseason, the Cowboys signed two veterans and drafted two rookies at the position.

But not all hope is lost for Vaughn. The Cowboys have a new coaching staff and it happens to include a former friend of Deuce: OL coach Conor Riley. Could it be enough to influence roster cuts? Perhaps not but the offense will look different.

Let’s see if Deuce capitalizes on it.

DE Payton Turner

I don’t expect the numbers game to work out for Turner in the end. Let’s crunch them: Micah Parsons, Dante Fowler Jr., Donovan Ezeiruaku, and Marshawn Kneeland are all virtual locks to make the 53-man roster. 

That gets us to four edge rushers and we can expect the average NFL roster to carry five guys. Can Turner beat Sam Williams for the fifth spot?

Williams is obviously liked by the franchise as a former second round pick but Turner is a former first-round selection that if healthy, could finally put the pieces together. 

WR Jalen Cropper

This one is a tricky one, too. Say the Cowboys carry six wide receivers on the roster. Below is my projection: 

• CeeDee Lamb
• George Pickens 
• Jalen Tolbert
• KaVontae Turpin
• Jonathan Mingo
• Ryan Flournoy

Realistically, the one spot Cropper can fight for is Flournoy's. Cropper was a OTAs/minicamp standout which really doesn't mean much until the pads come on in training camp. But he has a chance. 

LB Justin Barron

Barron is one of two UDFA rookies on the list and for good reason. He's a special teams ace, logging 949 snaps there at Syracuse. That can be an important tiebreaker when you're fighting for that 53rd spot on the roster. 

Barron was one of the highest-paid UDFAs on the Cowboys' class. 

DB Alijah Clark 

Similarly to Barron and also a fellow former Syracuse player, Clark got paid big time by the Cowboys. He was one of the highest-paid UDFAs across the league going by guaranteed money. 

Clark's versatility to play all across the defensive backfield could be enough to entice the Cowboys coaching staff to keep him around for depth purposes. Consider this from a past article:

As to why the Cowboys are so high on Clark, it likely has to do with his versatility, which he displayed in college by logging snaps all over the field. That includes 155 snaps in the box, 154 in the slot, and 259 at free safety in 2024, per PFF. That's the kind of calling card that makes you appear like a hidden gem.