In a large bowl, mix together pecans, chocolate chips, sugar, and cinnamon. Set aside.
Brush a 15 x 10 x 1-inch baking sheet lightly with melted butter. Preheat oven to 325°F. (177°C)
Layer 8 sheets of phyllo dough on the bottom of the baking sheet brushing each sheet with butter.
Sprinkle 2 cups of filling mixture over the buttered sheets.
Top with 4 more sheets of phyllo brushing each sheet with butter.
Sprinkle with remaining filling mixture and top with remaining phyllo sheets/butter.
Place toothpicks along the side of baking sheet every 2.5-inches.
Lightly cut across at at an angle between toothpicks forming a diamond pattern.
Bake for one hour.
To Make the Syrup
In a medium sauce pan, stir together orange juice, water, sugar, honey, and lemon juice.
Bring to a boil, then reduce heat and simmer for 20 minutes. Cool completely.
Remove the baklava from the oven and allow to cool for about 10 minutes, then pour the cooled syrup evenly over the top.
Leave the baklava uncovered at room temperature for several hours (or overnight). The syrup will soak in, the chocolate will settle, and the phyllo will stay crisp on top. Cut through all of the layers to separate before serving.
Notes
To make half with chocolate and half without in the same pan:
Mix half pound of pecans, 6 tablespoons sugar, and 3/4 teaspoon cinnamon in separate bowls.
Add 6 ounces of mini chocolate chips to one of the bowls.
Follow the instructions, only spreading 1/2 of each mixture over the phyllo sheets in the pan.
Let frozen phyllo thaw overnight in the fridge. Rushing it on the counter will make sheets stick and tear.
Tips
As you work, cover the stack with a slightly damp towel or plastic wrap. Even a few minutes exposed will dry phyllo out, making it brittle and tough to separate.
Use melted cultured butter like Kerrygold or Plugra for brushing between layers. It brings a rich flavor and helps sheets bake up crisp.
Higher cacao (69%–72%) means more cocoa flavor and less sugar. This balances the honey syrup and sweet nuts, keeping flavors grown-up and balanced.
Don’t pulverize the nuts, use a knife or pulse in a food processor for coarse bits. You want a mix of small chunks for body and crumbs for a tight, lush layer.
Don’t oversaturate the phyllo with butter, but make sure every sheet has a thin, even coat. This is what bakes up into those crisp, flaky layers that contrast beautifully with gooey chocolate.
Room temperature: Store in a sealed container for up to 3 days, baklava stays crisp and flavors intensify overnight.
Refrigerator: If keeping longer, refrigerate for up to 10 days, though the pastry may soften slightly.
Freeze for later: Freeze tightly wrapped portions for up to 3 months. Thaw at room temp for a few hours. To revive crispness, pop the thawed baklava in a low oven for a few minutes, just be careful not to dry it out.