First Step: Preheat Smoker and Prepare BaconPreheat your smoker to 250°F (121°C), using mild or fruit woods like pecan or apple to avoid bitterness. Place the thick-cut peppered bacon in a cast iron skillet or smoker-safe pan and cook over medium-high heat for 2 to 5 minutes per side until the fat is rendered but the bacon is not fully crisp. Remove bacon and drain on paper towels, leaving the rendered fat in the pan.

Second Step: Sauté AromaticsAdd diced onions and jalapeños (or bell pepper for milder heat) to the bacon grease in the pan. Sauté for 3 to 6 minutes until the onions turn translucent and the vegetables soften, bringing out their natural sweetness and aroma.

Third Step: Incorporate Sweeteners and SpicesStir in dark brown sugar and chili powder if using, and cook for 30 to 60 seconds until fragrant. This step builds the base for the sweet and smoky sauce that will coat the beans.

Fourth Step: Combine Beans and Sauce IngredientsRemove the skillet from direct heat and mix in the canned pork and beans with their liquid, BBQ sauce, apple cider vinegar, molasses, Dijon and yellow mustards, Worcestershire sauce if using, and bay leaves. Stir thoroughly to combine all flavors evenly.

Fifth Step: Add Bacon and Smoke the BeansScatter the cooked bacon pieces over the top of the bean mixture. Place the uncovered skillet in the smoker. Smoke the beans for 2.5 to 3 hours, stirring occasionally every 60 to 90 minutes. During this time, the beans will thicken and absorb the smoky flavor, and the bacon fat will render further, enriching the dish.

Final Step: Broil and ServeFor a crispier bacon finish, optionally broil the beans for 2 to 3 minutes after smoking, watching carefully to avoid burning the sugars. Remove bay leaves before serving. Let the beans cool slightly then serve warm as a hearty, flavorful side.