Who Knew Chuck's Zachary Levi Could Sing?

05/07/2010 AT 02:00 PM EDT

If playing a tech geek-turned-super spy out to protect national security on the hit show Chuck isn't enough, Zachary Levi has signed up for another mission: Katharine McPhee's unlikely costar and duet partner in her latest music video for "Terrified."

The song, penned by American Idol judge Kara DioGuardi, was originally recorded by singer-songwriter Jason Reeves for McPhee's second album, Unbroken. But when the former Idol runner up premiered her new video, it featured the 29-year-old Chuck star cozying up to McPhee in a recording studio.

Turns out Levi actually has a background in musical theater. The budding singer grew up performing in community plays and musicals near his childhood Ventura, Calif., home before he became Chuck the spy.

"I sing all day long on set," he said. "A lot of showtunes, Justin Timberlake ... whatever pops into my head, I sing it ... I think life should be a musical. I always hate it when people watch a musical and they go, 'Oh, it's so unrealistic. No one just breaks into song in the middle of their day.' Yeah, they do. They do, if they're me."

Though McPhee and Levi have known each other for some time, it wasn't until McPhee discovered that Levi would be singing in the upcoming Disney animated film Tangled, that she knew he could even hold a note. She then asked him to join her for the duet, which she was ready to shoot.

"He was such a blast; so funny and charming," she said, calling their time working together "an incredible pleasure."

Levi says the feeling was mutual:"Working with Katharine was awesome. She's a multi-talented girl, with a great heart. I hope I get the chance to work with her again."

Perphaps we'll see a future episode of Chuck involving the pop star?

Reporting by Marisa Laudadio

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