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1
Combine the sugar and egg yolks in the top of a double boiler over barely simmering water.
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2
Heat the mixture, whisking constantly, until thick enough to coat the back of a spoon, about 7-8 minutes.
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3
Remove pan from heat; whisk in bourbon; remove insert from the double boiler and set the custard aside to cool.
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4
When the custard has cooled, pour the coffee into a small bowl; sprinkle the gelatin over the coffee; set aside for 5 minutes.
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5
Transfer the coffee mixture to a small saucepan and gently heat, whisking until the gelatin has dissolved, about 1-2 minutes.
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6
Remove from the heat and gradually whisk into the custard mixture.
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7
Scrape the custard into a large bowl and refrigerate, whisking every few minutes.
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8
As soon as you refrigerate the custard, using a chilled bowl and chilled beaters, beat the cream using an electric mixer, until soft peaks form.
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9
Add in the Kahlua and vanilla and beat briefly.
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10
Add in the powdered sugar and beat briefly again, until stiff but not grainy.
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11
As soon as the refrigerated custard shows signs of thickening, remove it from the refrigerator and whisk in about 1/2 cup of the whipped cream until smooth.
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12
Add the remaining whipped cream in 2 parts, gently folding the mixtures together until evenly combined.
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13
Transfer the filling into the chilled pie shell, smoothing the top.
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14
Cover with loosely tented foil and refrigerate for at least 4 hours or overnight.
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15
Garnish with chocolate-covered coffee beans before serving.
