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Smoked Chuck Roast Recipe: Low and Slow BBQ Perfection

Master this smoked chuck roast recipe for tender, bark-crusted beef with a deep smoke ring. Perfect BBQ every time. Fire up the pit today!
Prep Time 20 minutes
Cook Time 8 hours
Total Time 10 hours 20 minutes
Servings: 6 servings
Course: Beef Recipes
Cuisine: American BBQ
Calories: 480

Ingredients
  

  • 4 lbs beef chuck roast bone-in or boneless, at least 2 to 3 inches thick for best results
  • 2 tablespoons kosher salt coarse grind preferred for better bark formation
  • 2 tablespoons coarse black pepper freshly cracked, 16-mesh style like Texas pitmasters use
  • 1 tablespoon garlic powder not garlic salt, straight garlic powder
  • 1 tablespoon smoked paprika adds color and a subtle sweet smokiness to the bark
  • 1 teaspoon onion powder optional but rounds out the rub flavor profile
  • 1 teaspoon cayenne pepper optional, add for a spicy kick in the bark
  • 2 tablespoons yellow mustard used as a binder so the rub adheres, burns off during the cook
  • 4 chunks oak or hickory wood chunks fist-sized chunks for the smoker, not chips - chunks provide longer smoke
  • 1 cup beef broth for spritzing during the cook to keep surface moist and build bark

Method
 

  1. Pull your chuck roast out of the refrigerator 45 to 60 minutes before the cook begins. Letting the meat come closer to room temperature promotes more even cooking throughout. Pat it completely dry with paper towels - moisture is the enemy of a great bark. A dry surface is what you need going into the smoker.
  2. Mix your rub: combine 2 tablespoons kosher salt, 2 tablespoons coarse black pepper, 1 tablespoon garlic powder, 1 tablespoon smoked paprika, 1 teaspoon onion powder, and 1 teaspoon cayenne if using. This is a bold Texas-inspired rub that will form that dark crackling bark you are after.
  3. Coat the entire chuck roast in a thin even layer of yellow mustard. This is your binder - it will not make the meat taste like mustard, it simply helps the rub grip the surface and creates a better bark. Work it into every surface including the sides and any crevices.
  4. Apply the rub generously to all sides of the roast. Press it in firmly with your hands - do not just dust it on. You want full coverage with a visible crust of seasoning on every surface. Let the seasoned roast sit at room temperature while you fire up the smoker.
  5. Fire up your smoker and bring it to a steady 225 to 250 degrees Fahrenheit. Add 3 to 4 fist-sized chunks of oak or hickory wood to the fire. Let the smoker settle into temperature and let the smoke run clean - you want thin blue smoke, not thick white billowing smoke, before you put the meat on. Thick white smoke will make your beef taste bitter.
  6. Place the chuck roast fat-side up directly on the smoker grate. Insert your wireless probe thermometer into the thickest part of the roast, avoiding any bone. Close the lid and let the low and slow magic begin. Do not open the lid for the first two hours - every peek drops your temp and slows the cook.
  7. After the first two hours, begin spritzing the surface of the chuck roast every 45 to 60 minutes with beef broth using a spray bottle. This keeps the surface moist, helps the bark develop properly, and adds a savory layer of flavor. Keep your smoker temp steady between 225 and 250 degrees. Add wood chunks as needed to maintain smoke.
  8. Monitor your internal temp. Around 160 to 165 degrees Fahrenheit, the roast will hit the stall - a phase where evaporative cooling causes the internal temp to plateau for one to two hours or more. This is completely normal. Do not panic and do not crank the heat. This is where patience separates a pitmaster from the rest.
  9. When you hit 165 degrees internal temp, pull the chuck roast off the smoker and wrap it tightly in two layers of unwaxed pink butcher paper. Add a small splash of beef broth inside the wrap before sealing it up. Return the wrapped roast to the smoker fat-side up. Re-insert your probe thermometer through the paper. This wrap technique powers you through the stall and locks in moisture.
  10. Continue cooking wrapped until the internal temp reaches 203 to 210 degrees Fahrenheit. At this temp range the collagen has fully converted to gelatin and the beef will probe tender - meaning a toothpick or thermometer probe should slide in and out with zero resistance, like pushing it into warm butter. This is your target, not just the number. Total cook time from start to this point is typically 6 to 8 hours depending on your smoker and the size of the roast.
  11. Once the chuck roast probes tender at 203 to 210 degrees internal temp, pull it off the smoker. Do not unwrap it yet. Place the wrapped roast in a dry empty cooler, close the lid, and let it rest the meat for a minimum of one full hour. Two hours is even better. This rest allows juices to redistribute throughout the beef and the internal temp to equalize. Skipping the rest means losing all those precious juices the moment you cut into it.
  12. After the rest, unwrap the chuck roast over your cutting board so you catch every drop of the accumulated juices. Slice against the grain for serving like a roast, or use two forks to pull and shred the beef - it will come apart effortlessly. Pour any collected juices over the top. Serve immediately and get ready to hear some serious compliments.

Nutrition

Calories: 480kcalCarbohydrates: 4gProtein: 42gFat: 32gSugar: 1g
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