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Smoked Chuck Roast

Smoked Chuck Roast

Edited by EastOak
Smoked Chuck Roast
East Oak
Community Creator
Andrew Desmond
No. 003 • 2026-10-12

“I wound up turning this smoked chuck roast into BBQ chuck sandwiches. The combination of smoky beef, pepper jack cheese, creamy coleslaw, pickles, and BBQ sauce made for one seriously satisfying sandwich.”

— Andrew Desmond
Prep Time:24 hrs (dry brine)
Serves:6-10
Smoke Time:6.5 hrs
Wood:Hickory
Temperature:250°F
Smoker Model:East Oak 30-In Electric Smoker Plus

Ingredients

For the Chuck Roast:

  • Main: 1 Chuck roast (approx. 5.3 lbs)
  • Binder: 2–3 tbsp Yellow mustard
  • Rub: Buc-ee's Brisket Rub
  • Wood: Hickory wood chips
  • Wrap: Butcher paper
  • Wrap: 2–3 tbsp Beef tallow

For the Sandwiches:

  • Martin's Potato Buns
  • Pepper Jack cheese
  • Smoked chuck roast
  • Coleslaw
  • Dill pickle chips
  • Kosmos BBQ Sauce

Pro Tips

  • Dry Brine: Dry brining the chuck roast for 24 hours in the refrigerator helps build flavor before smoking.
  • Watch the Temperature: Wrap the chuck roast in butcher paper with beef tallow when the internal temperature reaches 163°F.
  • Let It Rest: Once the chuck roast reaches 196°F, let it rest for 1 hour before slicing or pulling.
  • Build the Sandwich: Layer the smoked chuck roast with Pepper Jack cheese, coleslaw, dill pickle chips, and BBQ sauce for the ultimate BBQ sandwich.

Step-by-Step Instructions

1.

Dry Brine

  • Place the chuck roast in the refrigerator and dry brine for 24 hours.
2.

Season

  • Remove the chuck roast from the refrigerator and coat it with a layer of yellow mustard as a binder.
  • Generously season the roast with Buc-ee's Brisket Rub, making sure all sides are evenly coated.
3.

Preheat & Smoke

  • Preheat the smoker to 250°F and add Hickory wood chips.
  • Place the seasoned chuck roast in the smoker and cook at 250°F.
4.

Wrap

  • When the internal temperature reaches 163°F, wrap the chuck roast tightly in butcher paper with beef tallow.
  • Return the wrapped roast to the smoker.
5.

Finish

Smoked Chuck Roast Process
  • Continue cooking until the internal temperature reaches 196°F.
6.

Rest

Resting the Smoked Chuck Roast
  • Remove the chuck roast from the smoker and let it rest for 1 hour before serving.
7.

Build the Sandwiches

Finished Smoked Chuck Roast Sandwiches
  • Slice or pull the smoked chuck roast and pile it onto Martin's Potato Buns.
  • Top with Pepper Jack cheese, coleslaw, dill pickle chips, and Kosmos BBQ Sauce.
  • Serve and enjoy!
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