Measure popped corn into a large bowl. In a small saucepan, combine
sugar, syrup, water, and salt. Cover tightly and bring to a rolling
boil. Remove lid and add thermometer. Cook to 270-degrees; remove
from heat and stir in vanilla.
Pour cooked syrup over the popped
corn, stirring to coat corn. Cool completely, then run through a
food chopper. Melt chocolate coating in top of double boiler.
Stir ground popcorn into chocolate, using as much popcorn as the
chocolate will hold. Pack into chocolate lined molds or roll out
between waxed paper and cut into shapes with cookie cutters or
knives.
Recipe makes about 50 Popcorn Surprises.