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Mouth watering pulled smoked chuck roast in a off white bowl.

Pellet Smoked Chuck Roast

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  • Author: Denise Carrell
  • Prep Time: 15 min
  • Cook Time: at least 4-5 hours
  • Total Time: 0 hours
  • Category: BBQ
  • Method: Smoking
  • Cuisine: American
  • Diet: Gluten Free


If you fancy beef anything then you know that brisket rules the roost when it comes to the creme de’ la creme of BBQ. I gotta tell ya, though, that this rivals brisket when you are weighing both cost and taste. It’s important that you cook this cut of meat low and slow otherwise it will get tough and dry out. Resting your meat is also a must in order keep all the moisture from escaping. 


  • Chuck roast (at least one 3-4 pound cut)
  • 24 Tablespoons yellow mustard, (per roast) depending on the size of the roast
  • 3 Tablespoons of seasoning – Use a combination of garlic and onion powder, sea salt, pepper, and thyme, if you don’t have a favorite.
  • 1/3 cup beef broth (but any flavor will work)
  • 1/2 cup apple cider vinegar
  • 1 cup unsweetened apple juice (optional)


  1. Pull your chuck roast(s) out of the fridge and let them sit at room temperature for about 30-40 minutes. During this time, give them a rinse off and pat them dry with paper towels.
  2. Bind the roast horizontally, if necessarily so the meat stays hydrated and it’s easier to turn.
  3. Apply half the binder to each side of the roast making sure you cover the entire surface area.  
  4. Follow up by covering the roast liberally with your choice of seasoning. 
  5. Assuming it took you about 20ish minutes to prep your roast, you can fire up your pellet smoker to 250*F.
  6. After your smoker has come to temp, place your roast(s) directly on the grate, close the lid and cook for 2 hours.
  7. Meanwhile, mix the water and apple cider vinegar in a clean spray bottle. 
  8. After about 2 hours, the roast will begin to form a bark on the outside and look a little dry. Spray it down liberally with the apple cider/water combo. *
  9. You’ll continue to smoke the roast until it reaches an internal temp of 165*F, spraying it down every 30 minutes until it reaches temp. Flip it over every time you spray it. * This helps maintain even moisture.
  10. Once it reaches 165*F you can remove the roast and wrap it in pink butcher paper *(see notes) OR you can leave your meat on the smoker and continue to spray it down every 30 minutes or so. If you leave it on your smoker, skip to step 13.
  11. If you choose to wrap your roast, heat up your stock till it’s warm. Cold stock will cool down the roast too much and boiling stock will par cook it. You want it close to the temp of your roast.
  12. Add your stock to your roast, wrap it and place it on a baking sheet before you put it back on your smoker. If you use the temp probe of your smoker, insert thermometer by puncturing through the paper on the top.
  13. Continue smoking until the temp of your roast reaches 205 degrees F then remove the roast/pan from the smoker.
  14. If you haven’t wrapped your roast yet go ahead and wrap it. Place it on a tray and wrap the tray in an old towel and place it in a cooler.
  15. Let your meat rest at least an hour before cutting or shredding it. I’ve even let it in a cooler for up to a few hours and as long as the cooler is full (fill in empty space in your cooler with more towels). It will maintain its warmth. Resting your meat is highly necessary to keep the moisture in the meat.  


*If you run out of the water/ACV combo, you can mix up another batch and continue to use that or sweeten things up a bit with apple juice. Don’t skip using the water/ACV combo though, as it tenderizes the meat. I use organic unsweetened since apples are sweet all on their own. Organic not only means no glyphosate but it also tastes much better.

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