Hey, I have a cool idea for his creeplings. In a possible homage to the movie "300," have a whole bunch of them pull him around in a chariot. Then when he dismounts, he could squish a bunch of them.
Okay, more seriously though - if they're going to keep the ninjakats, they *need* good martial arts scenes. I want to see the Swat Kats' martial arts prowess versus two of Dark Kat's top henchman. The show is in dire need of a scene or two like that. Imagine getting some professional fight choreographers to design something like this.
I'm not an expert on fighting styles, but given T-Bone's larger size, I wonder if he would be more likely to use some kind of grappling or wrestling style where he grabs his enemies and throws them around a lot.
THIS because as much as I love technology and gadgets, I like seeing some hand-to-hand too. You got to see more of Jake's MA in Deadly Pyramid, and in a few others I enjoyed T-Bone breaking stuff throwing people around. I think they always intended for T-Bone to be a brawler while Jake a more calculating martial artist. It fits directly with their temperaments. T-Bone = pirate and Jake = ninja X3
Regarding Dark Kat, I always gathered he was basically Satan (which by definition means "adversary") or at least, someone who sold their soul. When people are evil for the sake of evil, it means they're submitted to and controlled by a higher principality of evil in exchange for power. I mean just LOOK at him; purple with a skull face and little demon monsters around him. I would LOVE if he had a deceptive side to him, like transforms from a straight-laced yet imposing judge by day to a possessed maniac by night.
I think there are two kinds of evil. Evil that people conjure up by themselves and then evil that is inspired by a greater force behind the curtains. The former are the practical villains that are just in it for the money and pleasure. The latter are those who hate everything including the Man Upstairs^ and will get back at said Man Upstairs by sabotaging the lives of others for the sheer joy of revenge, like a kamikaze pilot. They will use deception, make poisonous things as attractive as possible just to get you to bite then laugh as you go down in flames. They will use small deceptions to creating entire systems that are deeply entrenched in societies.
If DK is a judge that means he can present himself as an "angel of light" by day but pull back the curtain and watch out! I think DK is a great candidate for this dualistic dynamic in terms of character design and the bit we get of his goals. Would they dare to touch on such evil because I don't think it gets more ultimate than selling one's soul.
Like others here have stated, he just needs to be streamlined.