Step 1: Season the Chicken (5 minutes)
Pat the chicken thighs dry with paper towels—this helps the seasoning stick. In a small bowl, combine the smoked paprika, garlic powder, onion powder, salt, and pepper. Rub this spice mixture all over the chicken thighs, getting both sides. Don't skip this step! These spices create a flavor foundation that straight BBQ sauce alone can't achieve.
Step 2: Layer the Slow Cooker (5 minutes)
Scatter the sliced onions across the bottom of your 6-quart slow cooker. This creates a flavorful bed and prevents the chicken from sitting directly on the bottom. Arrange the seasoned chicken thighs in an even layer on top of the onions. They can overlap slightly, but try to keep it relatively even.
Step 3: Add Liquid and Initial Sauce (2 minutes)
Pour the chicken broth around the edges of the slow cooker (not directly over the chicken—we want to preserve that spice rub). Now add 1 cup of BBQ sauce, drizzling it over the chicken. Don't use all the sauce yet—we'll add more later for better flavor. Add the apple cider vinegar and sprinkle the brown sugar over everything.
Step 4: Slow Cook (4-6 hours)
Cover and cook on LOW for 5-6 hours or HIGH for 3-4 hours. The chicken is done when it reaches 165°F internal temperature and the meat pulls away from the bone easily. I usually go with LOW because I can start it in the morning and forget about it until mid-afternoon. Your house will smell absolutely incredible about 2 hours in.
Step 5: Shred the Chicken (10 minutes)
Using tongs, carefully transfer the chicken to a large cutting board. The meat will be fall-apart tender, so be gentle. Discard the skin and bones (they should come off effortlessly). Using two forks or meat claws, shred the chicken into bite-sized pieces. Don't shred it too finely—you want some texture.
Step 6: Create the Final Sauce (5 minutes)
Here's where the magic happens. Skim off any excess fat from the cooking liquid in the slow cooker (I usually get about 2-3 tablespoons off the top). Use a ladle to transfer about 1 cup of the cooking liquid to a large bowl—this liquid is loaded with flavor. Add the remaining 1 cup of BBQ sauce to this liquid and whisk together. Add the shredded chicken to this bowl and toss everything together. The chicken should be well-coated but not swimming in sauce.
Step 7: Return to Slow Cooker (Optional but Recommended)
Return the sauced chicken to the slow cooker and set it on WARM. This keeps everything at the perfect serving temperature and allows the flavors to meld for another 15-30 minutes before serving. If you're serving immediately, you can skip this and go straight to assembling sandwiches.
Step 8: Toast the Buns and Assemble
Lightly butter your buns and toast them in a skillet or under the broiler for 1-2 minutes until golden. This prevents soggy sandwiches—a crucial detail that David insists makes all the difference. Pile the BBQ chicken generously on the bottom bun, top with coleslaw if using, add pickles, and cap with the top bun. Set out extra BBQ sauce so guests can add more if they want.
