Step 1: Preheat oven to 250F. Coat the bottom and sides of a large roasting pan with nonstick vegetable spray. Place popped corn in roasting pan.
Step 2: In a heavy saucepan, slowly melt butter; stir in brown sugar, corn syrup, and salt. Bring to a boil, stirring constantly. Boil without stirring for an additional 5 minutes. Remove from heat; stir in baking soda and vanilla. Gradually pour over popped corn, mixing well. Bake for 1 hour, stirring every 15 minutes. Remove from oven, cool completely. Break apart into large chunks or bite-sized pieces.
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