Cook Bacon and Aromatics: In a cast iron pot over medium-high heat, add chopped thick-cut bacon and cook until it turns golden and crispy, about 5–7 minutes. Stir in finely diced onion and green bell pepper, cooking until softened, about 4–5 minutes. Add minced garlic and sauté for an additional minute.

Build Sauce: In a mixing bowl, combine BBQ sauce, ketchup, brown sugar, molasses, apple cider vinegar, yellow mustard, Worcestershire sauce, smoked paprika, salt, and a sprinkle of black and cayenne pepper. Stir until fully incorporated into a rich and glossy sauce.

Add Beans: Drain and rinse the navy or pinto beans, then add them to the pot with the bacon and aromatics. Pour the prepared sauce over the beans, stirring until every bean is generously coated. If too thick, add a splash of water or chicken broth.

Setup Grill: Preheat grill to approximately 300–325°F. Position cast iron pot away from direct flames on the grill grates.

Grill: Cover pot with a lid and let it grill for 1.5 to 2 hours, stirring every 30–45 minutes. Add water if needed. Ready when liquid has thickened to a beautiful, sticky sauce.

Taste and Adjust: Taste beans for seasoning. Adjust sweetness with more brown sugar or tanginess with more apple cider vinegar as desired.

Serve: Remove pot from grill and let BBQ Baked Beans rest for a few minutes. Garnish with chopped green onions and crispy bacon bits. Serve warm.