Grilled BBQ chicken is a backyard classic, juicy, smoky, and layered with caramelized sauce. Whether you’re cooking for a casual family dinner or hosting a summer cookout, mastering grilled chicken gives you a go-to crowd-pleaser. But behind its simplicity lies technique. This expert guide covers everything from selecting cuts and prepping chicken to choosing the right grill and solving common cooking issues, plus top tools and grills from Aosom to elevate your results.

1. Selecting the Right Chicken Cuts

Grilling chicken starts with choosing the right cut for your goals, whether you’re going for fast cooking, bold flavor, or a perfect balance.

Chicken Breasts

Lean and protein-rich, chicken breasts are a healthy choice but can dry out easily due to low fat content. Brining and using indirect heat help retain moisture. Skinless versions suit lighter meals, while skin-on adds flavor. Pound thick cuts for even cooking.

Thighs

Thighs are juicy, flavorful, and forgiving on the grill. Their fat content makes them perfect for bold marinades. Grill bone-in thighs over medium heat for crispy skin and deep flavor.

Drumsticks

Drumsticks are crowd-pleasers, especially with kids. Their dark meat stays moist even at higher heat. Sear first, then finish on indirect heat for tender results.

Wings

Wings grill quickly and crisp up beautifully thanks to their size and fat content. Great for bold sauces and glazes. Use indirect heat or a grill basket to prevent flare-ups.

Bone-in cuts hold moisture better and are more flavorful, while boneless options offer speed and ease.

2. Grill BBQ Chicken on Gas vs. Charcoal Grills

Whether you’re working with a gas grill or a charcoal setup, the grilling process for BBQ chicken needs a few adjustments to match the equipment. Here’s how to do it right with both.

Grilling BBQ Chicken on a Gas Grill

Gas grills are all about control and speed. They’re perfect for weeknight BBQ or when you want reliable, repeatable heat.

Steps:

• Preheat your gas grill to medium heat (around 375–400°F).
• Create two heat zones by turning off one burner or lowering it significantly.
• Start chicken on the indirect heat side, lid closed, to cook it through gently.
• Move to direct heat for the final 5–7 minutes to sear and caramelize the sauce.
• Apply BBQ sauce during the last 5–10 minutes, layering for flavor.

For precise, high-output chicken grilling, a grill like the Outsunny 52″ 4+1 Burner Gas Grill offers generous cooking space, independent burner control, and a built-in warming rack to manage different cooking zones effectively.

Grilling BBQ Chicken on a Charcoal Grill

Charcoal grills deliver smoky flavor and high heat but require more attention and prep.

Steps:

• Light your charcoal using a chimney starter and wait until coals ash over.
• Bank the coals to one side to create two zones: direct and indirect heat.
• Begin cooking the chicken on the indirect side with the lid closed to infuse it with smoke.
• Move to the direct side for the final sear and sauce caramelization.
• Adjust vents to control heat, and add wood chunks for extra smoky flavor.
  

Recommended Gear: The Outsunny 22″ Charcoal Grill features vent control, a warming grate, and bottom storage for charcoal and tools—ideal for traditional-style grilling.

3. Brining, Marinating, and Rubs: Essential Prep Techniques

Your flavor foundation starts before the grill is even hot.

Brining for Moisture

Brining adds internal moisture by soaking chicken in a saltwater solution for 30 minutes to 4 hours. Perfect for lean cuts like breasts. Adding herbs, garlic, or citrus to the brine can further infuse flavor and aromatics into the meat. For those who grill often, consider a compact, reliable heat source like the Outsunny 18″ Charcoal Grill with Wheels, which is perfect for backyard prep and quick chicken grilling sessions.

Marinating for Flavor

Use acidic or oil-based marinades with herbs, spices, or yogurt. Marinate for at least 1 hour or overnight. Acidic ingredients like vinegar or lemon juice help tenderize the meat while bold spices build surface complexity.

Rubs for Crust

Dry rubs enhance browning and create a flavorful crust. Apply just before grilling or up to 24 hours in advance. Use coarse salt, smoked paprika, black pepper, and brown sugar for a balanced base rub, and layer with custom spices depending on your flavor preference.

4. Preparing Chicken for the Grill

Proper preparation ensures even cooking and food safety.

• Trim excess fat to reduce flare-ups.
• Remove skin for a lighter dish or keep it on for added flavor and moisture. If needed, remove after grilling to reduce fat.
• Pat dry after marinating for better browning and grill marks.
• Safe storage: Refrigerate chicken until 30 minutes before grilling. Use a cooler if prepping outdoors, and keep raw meat separate.

5. Choosing and Setting Up Your Grill

Your grill affects both performance and taste. Here’s how to choose wisely:

For high-capacity grilling, consider the Outsunny 52″ 4+1 Burner Gas Grill, which features four burners, a warming rack, and side shelves—ideal for hosting gatherings or cooking multiple cuts at once. If you prefer the traditional smoky flavor of Charcoal Grill offers a compact yet capable solution with vent control and bottom shelf storage for better airflow and heat management.

6. How to Create a 2-Zone Grilling Setup

This technique helps balance searing with controlled cooking:

1. Pile coals or turn burners on one side.
2. Leave the opposite side cooler.
3. Sear meat on the hot side.
4. Move to a cooler zone to finish slowly.
   

This prevents burning and allows you to manage different cuts simultaneously.

7. Grill Temperature and Timing Guidelines

Use this grill temperature chart as a cheat sheet:

8. How and When to Flip Chicken for Even Cooking

Flip chicken only once or twice to avoid moisture loss. Let it release naturally from the grill to prevent sticking. Rotate pieces for balanced cooking. Always use tongs to maintain the texture and prevent piercing.

9. Applying BBQ Sauce Without Burning It

Timing is everything with sugary sauces:

• Wait until the last 5–10 minutes to apply sauce.
• Layer gradually: apply, grill 2–3 minutes, reapply.
• Let each coat caramelize to build flavor without burning.
  

10. How to Tell When Chicken Is Fully Cooked

Use a meat thermometer for accuracy:

The internal temperature for grilled chicken should be carefully monitored to ensure safety and optimal texture. Breasts and wings are done when they reach 165°F, while thighs and drumsticks require a slightly higher temperature of 170°F due to their darker meat and higher fat content.

11. Top BBQ Sauces and Flavor Pairings

Sauce choice can define the experience:

Homemade sauces add personality. Store-bought brands offer convenience.

12. Serving and Presentation Tips

Make your BBQ chicken shine at the table:

• Let it rest for 5–10 minutes before cutting.
• Slice against the grain for tenderness.
• Serve with sides like baked beans, slaw, mac & cheese, or grilled corn.
• Add garnish: Fresh herbs or citrus wedges boost appearance and aroma.

Grilling BBQ chicken is a rewarding ritual, made easier with the right know-how and gear. Whether you’re perfecting thighs on a rotisserie or crisping wings over charcoal, Aosom’s grill selection ensures you deliver juicy, flavorful chicken every time. Explore our collection and become a master of the backyard BBQ.

FAQs

Q: Why does grilled chicken stick to the grates even when they’re oiled?

Chicken often sticks when the grill isn’t hot enough or the meat goes on too wet. Always preheat the grill thoroughly and pat the chicken dry before placing it on the grates. Let the meat naturally release before flipping, forcing it too early can cause tearing.

Q: How can I keep BBQ chicken warm without drying it out?

To keep grilled chicken warm without losing moisture, tent it loosely with foil and place it on the indirect heat side of the grill or in a warm oven at around 200°F. Avoid wrapping it tightly, which traps steam and softens the texture.

Q: How do I get a smoky flavor on a gas grill?

To add smoky flavor on a gas grill, use a smoker box filled with soaked wood chips and place it over a lit burner. Close the lid to trap the smoke, mimicking that classic charcoal aroma without changing your setup.

Q: What’s the best way to grill chicken in cold or windy weather?

Grilling in bad weather requires preparation. Use a grill with a well-insulated lid and wind guards. Preheat longer than usual and avoid lifting the lid too often to maintain steady heat. Monitor internal grill temperatures closely for consistent cooking.

Q: How do I control flare-ups while grilling chicken?

When flare-ups happen, move the chicken to a cooler zone and close the lid to suffocate the flames. Keep a spray bottle of water handy, but only use it on the grates, not directly on the food, to avoid steaming or washing off your seasoning.