Pat dry and trim. Use paper towels to pat the chicken thighs dry. Trim excess fat if needed. Dry skin equals better browning and a crispier finish.
Mix the dry rub. In a small bowl, combine salt, pepper, smoked paprika, garlic powder, onion powder, and chili powder if using.
Season the chicken. Rub the thighs with oil, then sprinkle the dry rub all over, getting under the skin where possible.
Let sit 10–15 minutes at room temp while you preheat your grill or oven.
Make the glaze. Stir BBQ sauce, honey, vinegar, Worcestershire, mustard, and smoked paprika in a saucepan. Warm over low heat for 3–4 minutes, just until glossy and smooth. Set aside.
Choose your cooking method. Grill: Preheat to medium (about 375–400°F).
Oil the grates. Place thighs skin-side down for 5–7 minutes to sear, then flip and cook 15–20 minutes more, flipping occasionally.
Oven: Preheat to 425°F. Arrange thighs on a foil-lined, rimmed sheet with a wire rack if you have one.
Roast skin-side up for 25 minutes.
Air fryer: Preheat to 380°F. Arrange in a single layer, skin-side up. Cook 16–20 minutes, flipping at 10 minutes.
Glaze and finish. When the thighs are almost done (internal temp around 165°F), brush with the honey BBQ glaze.
Cook 5–8 more minutes to set and caramelize the sauce. Aim for an internal temp of 175–185°F for meltingly tender thighs.
Broil for char (optional). If baking, switch to broil for 1–2 minutes to blister the glaze slightly. Watch closely so it doesn’t burn.
Rest and serve. Let the chicken rest 5 minutes.
Brush with a little extra warm glaze. Garnish with parsley or sesame seeds and serve with lemon wedges.