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chopped smoked chuck roast sandwich with mac and cheese, potato salad, and baked beans
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Pellet Smoked Chuck Roast

Prep Time 15 minutes
Cook Time 6 hours
Total Time 6 hours 15 minutes
Servings 24 Servings
Calories 230kcal
Author Mason Woodruff

Ingredients

  • 3 small Boneless Chuck Roasts about 2 ¼ pounds each*
  • ¼ cup Yellow Mustard optional
  • 2 Tablespoons Kosher Salt
  • 2 Tablespoons Black Pepper
  • 2 Tablespoons Chili Powder ancho or guajillo, preferably
  • 2 Tablespoons Dark Brown Sugar
  • 2 Tablespoons Ground Coffee
  • 1 Tablespoon Garlic Powder
  • 1 Tablespoon Onion Powder

Instructions

  • Mix the dry rub ingredients together in a large bowl. Coat the roasts in mustard or your choice of binder before seasoning with the dry rub on all sides. For best results, place the seasoned roasts on a wire rack over a sheet pan in the refrigerator overnight or up to 24 hours before smoking.
  • To smoke the roasts, preheat a smoker** to 250ºF with the lid closed for at least 15 minutes.
  • Smoke the roasts for about 3-4 hours until the internal temperature reaches 155ºF to 165ºF and a nice bark has formed. (I recommend using your grill's probe or a wireless thermometer to alert you when the roasts come to temperature.)
  • Tightly wrap the roasts in butcher paper or heavy duty foil before smoking an additional 2-3 hours until the internal temperature reaches 203ºF to 205ºF.
  • Place the wrapped roasts on a sheet pan in your oven or in a cooler without ice to rest for 30-60 minutes before slicing or chopping.***

Notes

*Beef Selection Notes

You can use this same rub and smoking technique for a larger 4-5 pound roast. The cook times may be surprisingly close due to the water content in larger roasts, but you should always go by internal temperature instead of designated cook time. I would wrap a larger roast once it's in the 165ºF to 175ºF range.
Unlike my brisket style tri tip or pulled chuck roast tacos, I wouldn't spend more for prime cuts. There should be plenty of fat and marbling in USDA choice or even select roasts for juicy and tender smoked chuck roast. If you use select, you can add a bit of beef tallow or butter on top before wrapping.

**Smoker Notes

I used a Traeger Pro 575 and the Traeger Pro Blend wood pellets, which is a blend of oak, hickory, and cherry. Mesquite or the brisket blend pellets would also be great if you can get your hands on them.

***Slicing Notes

The grain on a chuck roast is a bit unique and is pretty tricky to consistently slice against. You can try to section it off to perfectly slice against the grain, but I find the meat is tender enough that thinly slicing is perfectly fine. And chopping obviously alleviates any concerns about grain direction.

Nutrition

Serving: 3ounces | Calories: 230kcal | Carbohydrates: 1g | Protein: 24g | Fat: 15g