Spread out the popcorn and 1 cup of the cashews out on two baking sheets. In a saucepan, combine the corn syrup and sugar. Bring to a boil and cook for 2 minutes; remove from heat. Carefully, add the peanut butter and honey. Stir until the peanut butter is melted, then add the vanilla. Working quickly, pour the mixture over the popcorn and cashews, and use two rubber spatulas to evenly coat the popcorn. Set aside to cool completely.
Fill a saucepot hallway up with water; set over medium heat and bring to a simmer. Turn the heat down to medium-low. Add the chocolate to a glass bowl and place the bowl over the pot of simmering water. Melt the chocolate, stirring occasionally.
Using a spoon or spatula, drizzle the popcorn with the chocolate. Sprinkle the remaining 1/4 cup cashews over the chocolate.