Smoked Chili Recipe

Smoked Chili Recipe

Smoked Chili Recipe

A big bowl of hearty chili is the perfect way to warm up on a cold day and I want to share with you my recipe for making Smoked Chili Recipe on the grill.

This Smoked Chili Recipe starts with a chuck roast that I smoke prior to making the chili. If you happen to have some left over brisket it does just as well in this dish.

Fire up your smoker and bring the temp up to 250⁰. Season the outside of the chuck roast or brisket with your favorite Rub. I use a mixture of my AP and other spices; here’s the recipe:

Chili Rub Recipe:

  • 1 Tablespoon Killer Hogs AP Rub (or your favorite, quality All Purpose Seasoning)
  • 1 Tablespoon Chili Powder
  • 1 Tablespoon Onion Powder
  • 1 Tablespoon Cumin
  • 2 teaspoon Paprika
  • 1 teaspoon Oregano
  • 1 teaspoon Cayenne Pepper
  • 1 teaspoon Chipotle Pepper

Combine these ingredients and liberally dust over all sides of the chuck roast. Place the roast on the smoker and let it cook for about 4 hours. The internal temp should be around 180 degrees.

Smoked Chili Recipe

I want it a little firm (not falling apart) for this Smoked Chili Recipe because it will be cubed and simmered for several hours until it’s melt in your mouth tender! Place the cubed roast in refrigerator overnight until ready to use.

For this chili I’m firing up my Big Green Egg; you can cook it on any type grill set up for indirect cooking just run temp between 275-300 degrees. I don’t add wood for this cook because the chuck roast has plenty of smoky flavor to add to the chili and I char grill the vegetables for even more grill taste.

Once the coals are hot, place the cooking grate in place, and let it heat up for a few minutes. The plate setter goes on later because I’m grilling the Poblano, Bell Pepper and Onion first.

Smoked Chili Recipe

Place each directly on the cooking grate over the hot coals for a few minutes on each side to char. Grilling the veggies makes them extra sweet. Remove the seeds from the peppers and chop everything into small pieces.

Then use a pair of high heat gloves and place the plate setter under the cooking grate to create indirect cooking on the Egg.

The last bit of prep for the Smoked Chili Recipe is my secret ingredient, 1 pound of spicy hot breakfast sausage. Just brown it in a skillet and drain off the excess oil. This kicks up the spice level a bit and gives the chili a rich flavor.

Smoked Chili Recipe

Now we’re ready to combine the ingredients for the chili. I use a 5 quart black iron pot and add the chopped vegetables and a 24oz can of diced tomatoes. Add 3-4 cloves of minced garlic, 3 Chipotle Peppers in Adobo Sauce, the chuck roast, and the spicy sausage. Dump in the chili seasonings and stir to combine.

Chili Seasoning:

  • 1/3 cup Sugar
  • 2 Tablespoons Killer Hogs AP Rub (or your favorite, quality All Purpose Seasoning)
  • 2 Tablespoons Chili Powder
  • 1 Tablespoon Ground Cumin
  • 1 Tablespoon Onion Powder
  • 2 teaspoons Paprika
  • 1 teaspoon Ground Chipotle Pepper
  • 1 teaspoon Ground Ancho Chili Pepper
  • 1 teaspoon Oregano
  • ¼ teaspoon Cayenne Pepper (more if you like it spicy)

Pour in ¼ cup of Worcestershire Sauce and 2 Tablespoons of your favorite Hot Sauce (you know I’m using my Killer Hogs Hot Sauce!), 2 Tablespoons Tomato Paste, and 1 quart of Beef Broth. Stir the chili to combine and place on the Big Green Egg uncovered.

Smoked Chili Recipe

Simmer the chili for 2 ½ hours and you’ll want to stir it a couple of times throughout the cook. At this point add 1 can of Chili Beans to the pot. Adding the beans at this point keeps them from getting a mushy texture. I know there’s a big debate about beans in chili but I personally like them in mine. If you don’t like beans just skip this step.

Keep simmering the chili for another hour and it’s ready to serve. Carefully remove the pot from the grill (wear some high heat gloves) and serve with your favorite chili toppings.

I like Shredded Cheese, Sour Cream, Fresh Cilantro and Lime wedges but you can serve it with anything you like.

Smoked Chili Recipe

This chili is rich and hearty with a smoky flavor, the tender bites of chuck roast melt in your mouth, and the spices have just the right heat. Gives this chili a try the next time you’re craving a hearty meal!

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Smoked Chili Recipe

Ingredients

  • 4lb Smoked Chuck Roast or Smoked Brisket cut into bite size pieces
  • 1lb Spicy Hot Breakfast Sausage
  • 1 Poblano Pepper
  • 1 Red Bell Pepper
  • 1 Sweet Onion
  • 24oz Diced Tomatoes
  • 3 Chipotle Peppers in Adobo Sauce chopped
  • 3-4 cloves Fresh Garlic
  • 1 quart Beef Broth
  • ¼ cup Worcestershire
  • 2 Tablespoons Hot Sauce
  • 2 Tablespoons Tomato Paste
  • 1 14oz can Chili Beans (optional)
  • Chili Seasoning (recipe below)
    Chili Seasoning:
  • 1/3 cup Sugar
  • 2 Tablespoons Killer Hogs AP Rub
  • 2 Tablespoons Chili Powder
  • 1 Tablespoon Ground Cumin
  • 1 Tablespoon Onion Powder
  • 2 teaspoons Paprika
  • 1 teaspoon Ground Chipotle Pepper
  • 1 teaspoon Ground Ancho Chili Pepper
  • 1 teaspoon Oregano
  • ¼ teaspoon Cayenne Pepper (more if you like it spicy)

Instructions

  1. Prepare Big Green Egg or other type smoker for indirect cooking at 300⁰.
  2. Grill Onion, Bell Pepper, and Poblano Pepper for a few minutes on each side and chop.
  3. Cube smoked chuck roast into bite size pieces. (Roast can be cooked ahead of time and refrigerated over-night)
  4. In a 5 quart iron pot add chopped grilled vegetables, diced tomatoes, chuck roast, spicy sausage, chipotle peppers, garlic, and chili seasoning; stir to combine.
  5. Add beef broth, hot sauce, Worcestershire sauce, and tomato sauce; stir to combine.
  6. Place iron pot on Big Green Egg and cook uncovered for 2 ½ hours stirring occasionally.
  7. Add Chili Beans, stir to combine and continue cooking for 1 additional hour.
  8. Remove from grill and serve with your favorite toppings (shredded cheese, sour cream, fresh cilantro, lime wedges)

Malcom Reed
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Smoked Chili Recipe

Comments 46

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  1. Your video says 4lb Chuck Roast and your text says 2lbs….. should I increase the ingredients for 4lb or is it just right for 4lbs?

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  2. Just made this chili. I didn’t use all the seasoning but saved it for my next time. It is awesome my husband is on his second bowl. Thank you

  3. What wood do you use when smoking the chuck? Also, did you grill the veggies the same day you smoked the chuck or right before you put the chili in the smoker? Seems like you need a higher temperature to char them, which would then make it longer to stabilize the BGE around 300 degrees… I’m a huge fan, you are my go-to on all things BBQ!

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      You could use any wood but I like pecan on chuck. I smoked the chuck the day before – but you can do it the same day. And I grilled the veggies right before – but once again, you can do it the day before. It all comes down to when you want to do the prep work.

      1. I am trying this chili this weekend. I have not missed yet with your receipies. Been following you for for a few years now. I am going for the cheese steak sandwich also.

  4. Malcom, I can tell you one thing you have your craft perfect to me. I’m trying your beef ribs this weekend!! I have been smoking for two years now with no complaints. So, I’m doing something right. Thanks.

    1. My hubby and I couldn’t agree more. We are so thankful we found Malcolm on YouTube. This chili is seriously the greatest thing ever thought up. Malcolm, if we didn’t have our roots here in Virginia, we would move to your neighborhood, if only to smell what you’re smoking! Making this chili for the 5th time right now for our church life group tomorrow and I’m about to win best meal of all time so I’ll make sure you get the credit you deserve! 🙂

  5. Made this with a few minor tweaks for a chili cook off at work today. The first place trophy is on my bookshelf now! Only entry without beans.

    Thanks! from Florida.

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  6. Great recipe. I cut out the poblano pepper and added habanero salt and black beans. Topped it cheddar and Fritos. I might try the pork belly burnt end recipe next and throw them into this recipe.

  7. This chili is insanely good. I’ve made this a few times now and I too have cut back the sugar a bit. The chuck roast is a great meat for this chili because it have enough body to not completely fall apart like a lot of other leaner cuts of meat.

  8. Used this recipe for a chili cook off and won 1st place! Chuck roast was perfect by the time the chili was done. I came home with an empty crock pot!

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  9. I have a chuck roast in the Kamado Joe Big Joe right now. I will be making your chili recipe tomorrow. I will be cutting back on sugar as well. Maybe a forth of a cup instead of a third. Keep posting and making videos of your great recipes I love watching and trying them.

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  10. Making this chili today to defend my title at a work chili cook off. The comments have me excited. Though. I think I could win just slicing up the smoked chuck and bringing that in. Will report back how it ended up.

  11. Looking forward to trying this recipe at the next chili contest here at work!! I have never made chili. Thank you so very much for the awesome posts! You’ve helped me greatly to make excellent brisket, pork, turkey, and more!! Blessings to you and your family and thank you again for the excellent advice and excellent recipes!!

    1. Hmm…Thinking to add bacon…but perhaps will throw off the chili flavor?? On one hand, thinking bacon makes everything better, on the other hand, don’t want to ruin a great recipe. We shall see. What say ye?

  12. Trying the Chili recipe this weekend. Then entering in a chili cook off at our church. Truely enjoy you site and videos . Its been a big help to me . Thank you

  13. Malcom, could you make the entire dish a day before serving and keep in the fridge over night? Reheat it again in a crock pot? Thanks for the videos, love the site!

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      Oh yeah – chili only gets better when it sits and the flavors really come together. You can heat it back up on the smoker or the stove – or a crock pot would do really good too (especially if your going to a tailgate or something like that).

  14. About how many servings does this recipe make? Been following you for quite some time now. Our Troop wants to enter it in a Camporee chili cook-off after I showed them this recipe.

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  15. Love this recipe with a slight variation: I substitute the chuck roast with 2.5 lbs smoked beef short ribs, 1 lb ground bison, and 1 lb ground elk. I also start by cubing and rendering 1/2 lb of bacon to cook down the onion, garlic, and peppers before adding the tomatoes and beef broth. Thanks for sharing Malcom!

  16. I’m doing my third batch today to enter into a competition. (I’ll report results later this week.) I’ve been using pork butt instead of the chuck roast. And I’ve been cranking up the cayenne – about 2x-3x what’s printed here. Great results and family review!

  17. Could I use a crock pot tocook the chili? Would I just leave the lid open? I want to smoke the meat but don’t want to use my smoker for actually cooking the chili.

  18. Could I use a crock pot to make the chili? I want to smoke the meat but not cook the chili in the smoker. Any suggestions?

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  19. Was waiting for the weather to turn to try this recipe and finally got to it this weekend. Goodness gracious, this was fantastic chili! All the prep work was definitely worth it. I put a little extra cayenne, and that made it a tad too hot for the family, so I’ll just stick to the recipe next time. We’ve tried a number of Malcom Reed recipes, and this one ranks up there with the best of them in my book. Thanks for sharing!

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