1. Check grill clearance first – ensure there’s enough vertical space for the chicken to sit upright with the lid closed.
2. Set up for indirect cooking: Remove grill grates if needed for height clearance. Light charcoal and let burn until coals are gray and ashy.
3. Create stable cooking surface: Place one aluminum roasting pan directly on top of the coals, ensuring coals are evenly distributed to support the weight of the pans.
4. Important safety note: Use heat-resistant gloves when handling pans over hot coals.

Prepare the chicken

1. Make the spice rub by combining all dry seasonings in a small bowl: kosher salt, seasoned salt, black pepper, onion powder, garlic powder, smoked paprika, cayenne pepper, chili powder, and dried thyme.
2. Prep the chicken: Remove giblets if present and pat completely dry with paper towels.
3. Apply butter: Rub softened butter all over the chicken, inside and out.
4. Season thoroughly: Apply the spice rub generously over the entire chicken and sprinkle some inside the cavity.
5. Prepare garlic: Cut the top off the garlic head to expose the cloves (don’t cut halfway through). Rub with olive oil and stuff inside the chicken cavity.
6. Rest the chicken: Let seasoned chicken sit for at least 30 minutes at room temperature (or wrap and refrigerate overnight for deeper flavor).

The Beer Can Setup

1. Prepare the beer: Open the can and pour out about ¼ of the beer if it’s too full – you need room for expansion.
2. Mount the chicken: Carefully lower the chicken onto the beer can opening, using the can and chicken legs as a stable tripod.
3. Test stability: Ensure the chicken sits upright and steady on the can.

Grill to Perfection

1. Set up cooking area: Place the chicken (still on beer can) inside the second aluminum roasting pan.
2. Position on grill: Carefully stack the pan with chicken on top of the pan already positioned over the coals.
3. Close and cook: Close the grill lid, leaving the top vent open for airflow. Cook for 1½ hours without opening the lid.
4. Check doneness: Internal temperature should reach 165°F in the thickest part of the thigh.

Finishing Touches

1. Carefully remove: Use heat-resistant gloves to remove the pans from the grill – everything will be extremely hot.
2. Rest the chicken: Let rest for at least 10 minutes before handling.
3. Remove beer can: Carefully lift chicken off the can (it will be very hot and may contain hot liquid).
4. Optional finishing: Brush with BBQ sauce before serving if desired.