Bring whipping cream to a simmer/bare boil in saucepan. Remove from heat and add chopped chocolate, chipotle chili powder and vanilla. Stir until smooth. Cool for 15-20 minutes.
Whisk together egg yolks and sugar in medium sized bowl. Slowly whisk cooled chocolate mixture into egg mixture. Whisk until smooth.
Preheat oven to 300 degress F. Spray 6 1/2c. custard cups with vegetable oil spray. Place cups in a shallow baking pan. (9 x 13" works well). Pour boiling water into baking pan so that water level comes halfway up sides of custard cups.
Bake until just set; about 40 minutes. Cool and refrigerate.
To add traditional sugar crust to custards, either use a brulee torch or add about 2 tsps. sugar to top of each baked custard and put under broiler until sugar is melted. Let cool until sugar is hardened.