Prep the pan and oven: Preheat oven to 425°F (220°C).
Line a rimmed baking sheet with foil for easy cleanup and set a wire rack on top. The rack helps the skin crisp. If you don’t have a rack, lightly oil the foil.
Pat the chicken dry: Use paper towels to dry the thighs thoroughly. Dry skin equals crisp skin.
Mix the rub: In a small bowl, combine salt, pepper, smoked paprika, garlic powder, onion powder, chili powder, and brown sugar.
Season the thighs: Drizzle thighs with olive oil.
Sprinkle the rub evenly on all sides. Gently lift the skin and season a little underneath for extra flavor.
Bake, skin-side up: Arrange thighs on the rack with space between them. Bake for 25 minutes.
Warm the sauce: While the chicken bakes, stir the BBQ sauce with apple cider vinegar if you like it a bit looser and tangier.
Glaze and continue baking: Brush a generous layer of BBQ sauce over the thighs.
Bake another 10–15 minutes, until the internal temperature reaches 175–195°F and the sauce is sticky.
Broil for char (optional): Switch to broil for 1–3 minutes to lightly caramelize the sauce. Watch closely to prevent burning.
Rest and serve: Let thighs rest 5 minutes. Brush with a little extra warm BBQ sauce, garnish with herbs, and serve.