Pat the chicken thighs completely dry with paper towels—this is crucial for better browning and crispy skin. In a small bowl, combine the salt, garlic powder, smoked paprika, chili powder, onion powder, black pepper, and brown sugar. Generously rub this mixture all over both sides of each chicken thigh, making sure to coat the skin and get some seasoning under any skin flaps. Let the seasoned chicken sit at room temperature for 10-15 minutes while you prepare the grill, which allows the flavors to penetrate the meat.

Heat one side of your grill to high heat (around 400-450°F) and leave the other side completely off or very low. This creates a two-zone setup that's essential for perfectly cooked chicken—the hot side will give you char and browning, while the cool side prevents the outside from burning before the inside cooks through. I like to place a water-soaked wood chip packet on the hot side for light smoking, which adds incredible depth to the final flavor.

Place the seasoned chicken thighs skin-side down on the cool side of the grill, positioned near but not directly over the heat source. Cover the grill and cook for 30-35 minutes, flipping the chicken every 10 minutes to ensure even cooking and prevent any side from burning. The internal temperature should reach 160-165°F during this stage. This slow, indirect cooking method keeps the meat juicy while allowing the skin to develop flavor from the ambient heat.

Once the chicken reaches 160-165°F, begin brushing it generously with BBQ sauce. Cover the grill and cook for 3-4 minutes, then flip the chicken and apply sauce to the other side. Cook covered for another 3-4 minutes. Repeat this process—flipping, saucing, and cooking—until the chicken reaches a final internal temperature of 175°F. I find that applying sauce in multiple thin layers creates better caramelization than one thick coat, plus it prevents burning. The final sauce layer should be slightly charred and sticky.

Transfer the finished chicken to a serving plate and let it rest for 5 minutes before serving. This brief rest allows the juices to redistribute throughout the meat, ensuring moist, tender chicken with every bite.