Pop your Popcorn: You can make this on the stovetop or in the microwave, however you prefer. Pop and set aside. (make sure to use plain)
Prepare the Bacon: Cook and crumble your bacon into small bite sized pieces and set aside. Make sure to reserve at least 4 tablespoons of bacon grease from cooking, we will add this to the caramel mixture.
Prepare the Pecans: Roast the pecans in the oven for about 5-7 minutes or until they are fragrant. Let them cool and then coarsely chop them. Set aside
Make the Caramel Sauce: In a medium saucepan, combine brown sugar, butter, and corn syrup.
Cook over medium heat, stirring constantly until the mixture begins to boil. Let it boil for 4-5 minutes without stirring. Remove the saucepan from the heat and carefully stir in the baking soda, salt, reserve bacon grease and vanilla extract. The mixture will bubble and thicken up.
Combine All Ingredients: Spray two very large mixing bowls lightly with cooking spray and divide the popped popcorn between the two bowls. Add half the chopped bacon and half of the toasted pecans to each bowl with popcorn. Pour the hot caramel sauce over the popcorn mixture. Stir gently to coat evenly. (I recommend using large tongs for this but don’t worry if you feel like you didn’t get every kernel coated, there will be extra time for this during the baking process!)
Bake the Popcorn: Preheat your oven to 250°F. Spread the popcorn mixture onto two large baking sheets in an even layer.
Stir the Popcorn: Bake for about 45 minutes, stirring every 15 minutes to ensure it is evenly coated and cooked. (This part is important! Make sure that every 15 minutes you open the oven and use heavy duty tongs to mix the popcorn with the caramel sauce…the sauce with melt as it bakes and allow you to coat the popcorn mixture more evenly)
Cool and Serve: Remove the popcorn from the oven and let it cool completely on the baking sheet. It will get crunchier as it cools. Break apart any large clusters of popcorn, and it’s ready!
*Important Note: This recipe makes A LOT of servings, feel free to cut it in half if you are making it for only a couple of people!