The Iron Knight was the final form Casey took in his first adventure through Wildside in Kid Chameleon. The Knight is armed with an enormous sword and an almost as large shield, and speaks in a stereotypical Medieval English dialect.
Having rescued Suzi as Bezerker, Casey switched to the Iron Knight persona when the pair were confronted with a massive tower Bezerker couldn't scale. As they ascended the tower, they were attacked by a pair of miniature bi-planes, but the Iron Knight destroyed both with a single swing of his sword. Upon reaching the top of the tower, the pair were attacked by a monstrous cyborg gorilla. The Iron Knight urged Suzi to take the Telepad out of Wildside while he engaged the monster. However, when his sword ws shattered, he decided Bezerker would be a more appropriate form to fight with. Unfortunately, his Chameleon powers chose that moment to give out, and he was left to fight the gorilla as plain old Casey.
The Iron Knight was later seen again in flashback, as Casey accepted that he would have to return to Wildside to rescue Brad.