If you’re looking for something besides traditional BBQ to cook this weekend, I have a great recipe for you today. I’m using Beef Chuck Roast cooked low and slow; then I’m making one mouth-watering sandwich.

Chuck Roast is one cut of meat that most people don’t associate with BBQ. Similar to brisket, chuck roast needs to cook for a long time to become tender.

It’s made up of different groups of the shoulder and contains a good bit of fat and collagen. This cut stands up well to long cooks and the fat melts away leaving moist, flavor-packed meat.

I bought 2 chuck roasts weighing 3lbs each. Chuck is considered a lesser cut of beef, so it’s common to find it under $3 per lb. This means you can feed a lot of people some good food without spending a lot.


Much like a pork butt or brisket it takes a while to cook a chuck roast. You want it to be close to falling apart in the end, so it takes some time. You can plan on a 6 hour cook easy depending on the size of the roast.

For this recipe I’m shooting for more of a beefy flavor than typical bbq, so the seasoning I use is savory based. I take my AP seasoning (Salt, Pepper, Garlic) and add a few things to it.

  • 1/2 cup Salt
  • 1/4 cup Garlic
  • 1/4 cup Onion Powder
  • 1/4 cup Chili Powder
  • 1/8 cup Black Pepper
  • 1 tea Ground Parsley
  • 1 tea Ground Oregano

Season all sides of the chuck roast with this mixture (this recipe is more than enough seasoning for 2 chuck roasts).


Now it’s time to light the fire. I’m looking for 250 degrees with a little mild pecan smoke for these chucks. Once the smoker is up to temperature, place the roasts directly on the grate and close the lid.

I’m using my Yoder (set & forget) today but any cooker will work as long as you can regulate the heat.


After 1.5 hours flip both roasts over and continue smoking. Keep adding pecan chunks as necessary and maintain the temperature at 250 degrees.


At the 3 hour mark the chuck roasts should be ready to pan. Take a thermometer reading here; it should read between 140-150 degrees. The meat won’t take any more smoke at this point, so it’s best to get it covered.

For these chuck roasts, I use a large steam pan to hold them both. The meat needs some additional liquid as well, so I pour in 32oz of warmed beef broth. If you want to change it up a little substitute red wine or even a dark beer, go for it.


Cover the pan with aluminum foil and place it back on the smoker still holding 250 degrees.

You’re looking at another 2-3 hours at least, so keep an eye on the pit and add fuel as needed.

You want to go more by the internal temp that the time – and the final target temperature is 195-200 internal. It’s not the end of the world if you overshoot the target temp on this cut of meat. There’s plenty of liquid in the pan to add moisture and you want it falling apart. This beef is for pulling, so we want the collagen and fat holding it together to completely dissolve.

When the thermometer is reading 195 and it feels like a knife sliding into hot butter, you know it’s done. Remove the pan from the smoker and let the steam escape for about 5 minutes. Rest the meat for at least an hour (I go for 2) before breaking it down. Even after two hours it will still be so hot you’ll need to wear hand savers and gloves.


When it’s done properly this meat will practically pull itself. Separate any fat that didn’t render and pull the pieces into small strands. If you don’t want to shred it by hand you can always use a couple forks or a pork puller… it will flake right apart after it cools a little.

I like to reserve the liquid from the large pan. That beef broth is rightly seasoned after you’ve cooked the chuck roasts in it. You can use it to add a little extra moisture to your pulled meat. Just ladle some of the liquid over the pulled meat… and you’re ready to serve.


Now, you can just serve this pulled beef the way it is. And it is some good stuff. But I like to make a pulled beef sandwich. It’s something great to serve for tailgates and football parties because it’s different and delicious.


For my Pulled Beef Sandwich here’s what you’ll need:

Pulled Beef
Onion buns
Caramelized Onions (recipe on the right side)
Horseradish Mayo*

*Horseradish Mayo Recipe
– 16oz Mayo
– 6oz Horseradish Cream Sauce
Mix together and place into a squeeze bottle.

All you do to make this sandwich is to split the onion roll and pile on a heaping serving of pulled beef. Then I just top with caramelized onions and Mayo.

It’s easy and folks go crazy over it. You get a little sweetness from the onions – and the horseradish mayo has just enough of a kick without being overpowering.

Give this recipe a try, your friends will thank you for it.

Malcom Reed

Killer Hogs BBQ Cooking Team
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About the Author

I am Malcom Reed and my brother, Waylon, and I are the Killer Hogs competition bbq team. Here at HowtoBBQright.com, I want to give you my secrets, methods and techniques you need to produce competition-quality BBQ. I want to give enough detail for BBQ novices, but still offer information that is useful for the professional BBQ cooks. I only focus on REAL bbq. And I take it seriously.

11 Comments on this article. Feel free to join this conversation.

  1. Ryan October 6, 2014 at 1:36 pm -

    Love what you’re doing man! When you say let the meat rest for up to 2 hours, do you mean to leave it wrapped in foil? Thanks again for all the awesome recipes!

  2. Administrator October 8, 2014 at 9:34 am -

    I always pull the meat off the smoker, open the foil and allow it to vent for 3 – 5 minutes. Then wrap it back up and put it in a dry cooler.

  3. Dale November 2, 2014 at 11:23 am -

    Love the chuck roast, something a little different and very tasty! Really like the videos keep them coming.

  4. denny February 1, 2015 at 11:22 am -

    Just put it on! I only have a 1.5 pounder because I only have 4 1/2 hours before we pull it out. I have faith

  5. Charles June 16, 2016 at 9:04 am -

    I use a lot of your recipes and they all turn out great.
    I am going to try this one and serve on New Orleans poboy bread. My question is do you think I could add a little of “The Rub” or Montreal Steak seasoning or would that be too much for the roast ?

  6. JOE June 16, 2016 at 11:22 am -

    I made this in my Bradley smoker. It came out great, kind of like a poor mans brisket!

  7. Patrick July 25, 2016 at 1:14 pm -

    Salty shoe leather.

    Total waste of perfectly good hamburger/soup meat.

  8. John September 15, 2016 at 6:14 am -

    Great recipe! Trying it out today!

  9. Ben September 23, 2016 at 10:15 am -

    Tried this last weekend and it turned out great. Smoked it in my electric smoker. Family loved it. Great flavor. Not sold on the slaw.

  10. Arthur November 4, 2016 at 1:51 am -

    Hi Malcolm

    As a newbie to smoking etc from “down under”, I want to thank you for your fantastic website, videos n many helpful tips n recipes. My second attempt at Boston Butt was very successful, n I finally realised what all the s,ok in fuss is about. I had the best most succulent tasty soft n juicy bit of meat I’ve ever tasted in my 70 years – thanks to you. Must say I also found Meatheads Amazing Ribs website extremely good also.

    I have one question if I may. You wrapped your pork butt in aluminium foil, and the juice gathered in the bottom, but in so doing (as it did in mine), made the bottom a bit soggy, n also softened the bark.

    So was wondering if you could use a baking dish with wire rack in the bottom so the juice can gather underneath without soggying the bottom, then cover with a foil lid and cook on to 195. Or would not having the close tighter wrap of the foil, would I lose something?

    Many thanks again
    Arthur (from down under Ozzie land, Australia.

  11. Rob January 29, 2017 at 9:49 am -

    Thanks for posting this. I have been trying to cook pulled beef for a while and can’t get it done. The beef is always tough and un-pullable (if that’s a word). I just put the beef in. I’ll post my results when done.

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