Prepare the Ingredients: Slice the smoked sausage into thick 1-inch rounds. Cut the fresh pineapple into bite-sized chunks, then chop the bell peppers and red onion into pieces similar in size to the pineapple. Keeping everything relatively uniform helps the ingredients cook evenly and creates a more attractive presentation on the skewers.
Make the Hawaiian BBQ Glaze: In a small mixing bowl, whisk together the barbecue sauce, pineapple juice, honey, brown sugar, Worcestershire sauce, and garlic powder until smooth and fully combined. For extra convenience, reserve a small portion of the glaze for serving after grilling.
Assemble the Skewers: Thread the sausage, pineapple, bell peppers, and onion onto skewers, alternating the ingredients for a colorful and balanced appearance. Leave a little space between each piece so the heat can circulate properly and encourage better caramelization.
Season the Skewers: Lightly brush the assembled skewers with olive oil. Sprinkle evenly with salt, black pepper, and smoked paprika to build flavor before they hit the grill.
Preheat the Grill: Heat your grill to medium-high heat, about 400°F (204°C). Clean the grates thoroughly and lightly oil them to help prevent sticking and create beautiful grill marks.
Grill the Kabobs: Place the skewers directly on the hot grill and cook for 10 to 12 minutes. Turn them every 2 to 3 minutes so all sides develop even color, light char, and attractive grill marks.
Begin Glazing: During the final 4 to 5 minutes of cooking, brush the skewers generously with the Hawaiian BBQ glaze. Continue rotating and glazing several times to build layers of sweet, smoky flavor while creating a glossy finish.
Watch for Caramelization: As the kabobs finish cooking, the pineapple should develop golden caramelized edges and the sausage should show light char and browning. The vegetables should be tender-crisp with slightly blistered surfaces.
Remove and Rest: Transfer the kabobs to a serving platter and let them rest for 2 to 3 minutes. This short resting period allows the glaze to settle and the flavors to fully come together.
Garnish and Serve: Drizzle with any reserved glaze and garnish with sliced green onions, chopped parsley, or toasted sesame seeds. Serve immediately while hot and enjoy the perfect combination of smoky sausage, sweet pineapple, colorful vegetables, and sticky Hawaiian barbecue flavor.