How Long to Cook Boneless Chicken Thighs on a Pellet Grill: The Perfect Timing Guide

Ever tried cooking boneless chicken thighs on your pellet grill only to end up with dry overcooked meat or worse—undercooked chicken that’s unsafe to eat? I’ve been there too! After much trial and error (and a few disappointed dinner guests), I’ve finally nailed down the perfect timing for juicy flavorful boneless chicken thighs on a pellet grill.

In this guide, I’ll share everything I’ve learned about cooking times, temperatures, and techniques to help you achieve pellet grill chicken thigh perfection every single time

Quick Answer: Cooking Time for Boneless Chicken Thighs

Boneless chicken thighs typically take 20-30 minutes to cook on a pellet grill at 350°F (177°C). However the exact time depends on the thickness of your chicken thighs

The most important factor isn’t time but temperature—always cook chicken thighs to an internal temperature of 165°F (74°C) for safety, though many chefs prefer 175-185°F (79-85°C) for more tender thighs.

Why Use a Pellet Grill for Chicken Thighs?

Before diving into cooking times, let’s talk about why pellet grills are awesome for cooking chicken thighs:

• Even cooking temperature: Pellet grills maintain consistent heat, reducing the risk of undercooking or overcooking
• Enhanced flavor profile: Wood pellets infuse your chicken with amazing smoky flavors
• Convenience: Set the temperature digitally and let the grill do the work
• Versatility: You can smoke low and slow or crank up the heat for a nice sear

My Traeger has completely changed how I cook chicken thighs—the flavor is unmatched, and I don’t have to babysit the grill constantly!

The Two-Stage Cooking Method

Many experienced grillers (including myself) swear by a two-stage cooking approach for the best results:

1. Stage 1: Cook at a lower temperature (around 250°F) for about an hour to allow the chicken to absorb that wonderful smoky flavor
2. Stage 2: Increase the temperature to 450°F and flip the thighs skin-side down to crisp up the skin

This method gives you the best of both worlds—deep smoky flavor AND crispy skin. It’s a game-changer!

Preparation Tips for Perfect Chicken Thighs

Before you even fire up your pellet grill, proper preparation is key:

Trimming and Drying

• Trim any excess fat (though leave some for flavor!)
• Pat the chicken thighs completely dry with paper towels
• This helps with browning and helps seasoning stick better

Seasoning Options

For a simple but delicious option:

• 2 tablespoons garlic pepper
• 2 teaspoons salt

Or get creative with your favorite rub! Apply your seasonings generously and let them sit on the chicken for at least 30 minutes (overnight in the fridge is even better).

Step-by-Step Cooking Process

Alright, let’s get cooking! Here’s my foolproof method:

1. Preheat your pellet grill to 250°F and close the lid
2. Season your chicken thighs with garlic pepper and salt (or your preferred seasoning)
3. Place the thighs on the grill with the skin side up
4. Smoke for 1 hour at 250°F to develop flavor
5. Increase heat to 450°F and flip the thighs so they’re skin-side down
6. Grill until the skin is crispy and browned to your liking
7. Flip them back over (skin-side up) and check the internal temperature
8. Remove when they reach 165°F (though 175-185°F will give you more tender results)
9. Let rest for 5-10 minutes before serving

Wood Pellet Recommendations

The type of wood pellets you use will significantly impact the flavor of your chicken thighs:

• Hickory or applewood: Balanced smoky and slightly sweet flavor
• Mesquite: Stronger smoke flavor
• Fruit woods (apple, cherry, pecan): Milder, sweeter smoke that complements chicken beautifully

I personally love using applewood for chicken thighs—it adds just the right amount of smoky sweetness without overpowering the meat.

Common Problems & Solutions

Problem: Dry Chicken Thighs

Solution: Use a meat thermometer and don’t overcook! Remember that boneless thighs are done at 165°F but are more tender at 175-185°F.

Problem: Chicken Skin Isn’t Crispy

Solution: Make sure to pat the chicken dry before cooking, and don’t skip the high-heat searing stage at the end.

Problem: Undercooked Chicken

Solution: Always verify doneness with a meat thermometer inserted into the thickest part of the thigh.

Problem: Inconsistent Results

Solution: Preheat your grill properly (10-15 minutes) and maintain a consistent temperature throughout cooking.

Enhancing Flavor with Marinades

While dry rubs are fantastic, marinades can take your chicken thighs to the next level:

• Marinate for at least 30 minutes, up to 24 hours in the refrigerator
• Use acid-based marinades (citrus, vinegar) to tenderize the meat
• Pat the chicken dry before grilling, even after marinating

A simple marinade I love includes olive oil, garlic, lemon juice, and herbs—it never disappoints!

Serving Suggestions

These pellet-grilled chicken thighs pair beautifully with:

• Grilled corn on the cob
• Creamy coleslaw
• Roasted garlic mashed potatoes
• Jalapeño cheddar cornbread
• Smoked scalloped potatoes
• Strawberry spinach salad

Storage and Leftovers

Got leftovers? Lucky you! Here’s how to handle them:

• Refrigerate in an airtight container for up to 3-4 days
• Reheat in a 350°F oven until warmed through to maintain crispy skin
• Freeze for up to 2-3 months wrapped tightly in plastic wrap or freezer-safe bags

Pro tip: I often cook extra chicken thighs specifically for leftovers—the meat is amazing in salads, pasta dishes, or homemade chicken soup!

FAQ About Cooking Boneless Chicken Thighs on a Pellet Grill

Can I use this method for bone-in chicken thighs?

Yes! You’ll just need to adjust cooking time—bone-in thighs typically take longer. The two-stage cooking method works great for bone-in thighs too.

Should I brine my chicken thighs before grilling?

While not necessary (especially for naturally juicy thighs), brining can enhance moisture and flavor. A simple brine of salt, sugar, and water for 1-2 hours works wonders.

What if my grill temperature fluctuates?

Try to place your grill in a sheltered area, especially on windy days. Using a grill blanket in cold weather can help maintain consistent temperatures.

Can I prep the chicken ahead of time?

Absolutely! You can season the chicken up to 12 hours in advance and store it covered in the fridge. This actually improves flavor and helps the skin dry out slightly for better crisping.

What are good substitutions for garlic pepper?

If you don’t have garlic pepper, mix black pepper, garlic powder, and a pinch of crushed red pepper for a similar flavor profile.

Final Thoughts

Cooking boneless chicken thighs on a pellet grill isn’t complicated once you understand the basics of time and temperature. Remember, the goal is juicy, flavorful meat with crispy skin—and that’s achieved through the two-stage cooking process and careful temperature monitoring.

With practice, you’ll develop an intuition for perfect timing based on your specific grill and preferences. Don’t be afraid to experiment with different wood pellets, seasonings, and techniques to find your perfect method.

Now fire up that pellet grill and get cooking! Your taste buds (and dinner guests) will thank you.