Remove excess fat and uneven skin from the thighs, leaving enough skin to cover each piece. Arrange the skin smoothly over the meat and blot dry.
Combine the Chili Lime Marinade
Combine olive oil, lime juice, lime zest, chili powder, smoked paprika, garlic powder, onion powder, ground cumin, kosher salt, black pepper, cayenne and honey in a medium bowl. Whisk until blended, then transfer a small portion to a separate container for basting.
Marinate Chicken Thighs
Add the marinade onto the chicken thighs and toss until they're completely coated. Cover and place in the refrigerator for 1—2 hours, then shake off any heavy coating before grilling.
Sear Chicken Skin-Down
Set up a two-zone grill and preheat the hot side to 425—450°F. Start the thighs skin-side down for 3—5 minutes, then turn and cook the opposite side for another 2—3 minutes. Adjust their position if the honey begins to scorch.
Move to Indirect Heat
Transfer the chicken to indirect heat at 325—350°F. Close the lid and cook until the thickest part registers 185—195°F, brushing with the reserved marinade near the end. Allow 12—18 minutes or longer for cooking.
Finish Up and Serve
Rest the thighs for 5 minutes after removing them from the grill. Add a squeeze of lime, chopped cilantro, and flaky sea salt before serving.
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Notes
Marinade Timing: Refrigerate the chicken for 1—2 hours for the best flavor. A 30-minute marinade works when you're short on time, but avoid exceeding 4 hours because the fresh lime juice can affect the meat's surface texture.
Better Skin Browning: Let excess marinade drip off before grilling. A heavy coating of honey and spices can darken before the skin has a chance to develop its crust.
Manage Flare-Ups: Keep the cooler side of the grill available throughout the sear. Dripping fat can ignite over charcoal, and moving the chicken away from the flames prevents the chili-lime coating from burning.