Start by warming a teaspoon of oil or butter in a small saucepan over medium heat. Add the minced garlic and let it cook just until it turns light golden and fragrant. Watch it closely here, because burnt garlic will turn the whole sauce bitter.
Pour in the ketchup, honey, Worcestershire sauce, hot sauce, black pepper, brown sugar, and lemon juice. Stir everything together and let it simmer on medium-low for 10 to 15 minutes, stirring occasionally so it doesn't stick. It's ready once it looks glossy and bubbly.
While the sauce simmers, rub the chicken thighs all over with oil so the seasoning has something to cling to. Sprinkle on the salt, pepper, and garlic powder, making sure every piece is evenly coated on both sides.
Place the chicken on a hot grill and let it sear undisturbed until it's golden brown on one side. Flip it over with tongs and let the other side brown too. This step builds flavor and locks in those nice char marks.
Once the chicken hits about 155°F internally, start brushing on the honey BBQ sauce generously. Flip it again so the sauce caramelizes on the grill, then repeat on the other side.
Keep cooking and basting until the chicken reaches a safe internal temperature of 165°F. This whole grilling process usually takes less than 20 minutes total, depending on how hot your grill runs.
Pull the chicken off the grill and let it rest for a couple of minutes before serving. This helps the juices settle back into the meat instead of running out onto your plate.