Cut the thick-cut bacon into bite-sized pieces using kitchen shears or a knife. Cook the bacon on the grill until crispy, rendering flavorful bacon fat.
Add chopped onions and minced garlic to the bacon fat. Sauté until the onions are translucent, absorbing the delicious smokiness.
Pour in two cans of baked beans (liquid included) into the cast iron over direct heat. Add BBQ sauce, ketchup, and chili powder. Stir to combine.
Enhance the smokiness by adding a teaspoon of liquid smoke. Adjust the quantity based on your preference.
Add brown sugar to achieve the perfect balance of sweetness. Start with a handful and adjust to taste. Remember, this is where you can tailor the flavor to your liking.
Allow the beans to simmer on indirect heat, absorbing the smoky essence. The cast iron skillet holds the heat, creating a slow-cooking effect.
After 20-25 minutes, open the lid to reveal a pot of beautifully simmered BBQ baked beans.