After you taste this Smoked Beef Chuck Roast Sandwich, you will forget about any other BBQ sandwiches!
This sandwich has all the tenderness of pulled pork but with that beefy goodness of brisket. I promise that this will be your new favorite smoked beef recipe this summer.
Smoked Chuck Roast Sandwiches
If you want to make a bunch of sandwiches to feed a crowd but don't want to go through all the time and effort to make smoked brisket pulled chuck roast sandwiches are a great alternative.
These pulled chuck roast sandwiches, also called "Chuckies," are easy to prepare and take much less time than a port butt or brisket.
If you want to serve the perfect Pulled BBQ Trio make sure to make my Smoked Pulled Pork and Pulled Chicken along with this recipe.
Ingredient List for Smoked Chuck Roast
Here is everything you will need to prepare the smoked chuck roast
- 4-5 Lb Beef Chuck Roast
- White Onion (Sliced)
- Bell peppers (multi-colored)
- Fresh Jalapenos
- Fresh Garlic Cloves
- Beer
- BBQ Dry Rub
- Worcestershire Sauce
- Soy Sauce
- Ketchup
- Honey
- Brown Sugar
- Beef Stock
- Hot Sauce
- Rolls
How to Make Pulled Smoked Chuck Roast
The process for making this recipe is very straightforward. Even though there are more ingredients listed above than I typically like in a recipe.
- Season The Chuck Roast. Don't worry about any binder for this. Just season the Chuck Roast on all sides with your favorite beef rub.
- Preheat the pellet smoker to 250 degrees F. Then, place the seasoned chuck roast on the grates. Leave it alone for three hours... No peeking
- While the beef is smoking, cut up all your onions, peppers, and jalapenos and set them aside. Set out all your other ingredients, and grab a foil pan.
- After 3 hours of smoking, place all your ingredients in the bottom of the pan, then place the chuck roast on top and cover with aluminum foil. Cook for another 3 hours covered.
- Carefully pull back the foil and probe the meat with a meat thermometer. You are looking for an internal temperature of around 205, but it's more important to see how tender the meat feels. The probe should go in without any effort or resistance. If it still feels tough, cover it and cook it for another hour.
- Once the chuck roast feels fall apart tender, use a pair of tongs to start shredding the meat, combining it with the onions and peppers.
- Serve the pulled chuck roast in the same foil pan, with some buns, pickles, BBQ sauce, and any other condiments you like.
What is a Chuck Roast?
Chuck roast is a large cut of beef. You probably had pot roast as a kid, which is the most popular chuck roast recipe I can think of. Chuck roasts are a tougher beef cut with a lot of connective tissue.
They benefit from a long cook time over indirect heat or low heat and the use of a braising liquid like beef broth combined with other spices like garlic powder, onion powder, kosher salt, and coarse black pepper.
Cooking Tips
Leftovers reheat great; some say they are even better the next day. I like to reheat the beef roast in the oven at a lower temperature, around 300 degrees F., for about 30 minutes.
Be sure to wrap the pan in layers of foil so it's completely sealed for best results. Keep a cookie sheet/sheet pan underneath the pan just in case there are any drippings that might dirty up the oven.
While the beef roast is smoking, you can place a water pan underneath the roast if you are worried about the meat drying out.
Placing a probe thermometer in the thickest part of the roast is a great way to monitor the cook without opening the pellet grill to take a temperature.
Once the roast reaches 165 degrees F during the smoking process, it has absorbed all the smoke flavor, and it's a good time to wrap.
Variations
You can use this same recipe with many different cuts of beef like London broil, boneless short ribs, eye of round, or bottom round, to name a few. Most of these cuts are common and can be found at your local grocery store.
The cooking times may differ, but make sure you cook the beef long enough so it shreds easily.
If you don't Have a smoker, you can most certainly make this recipe in a crockpot. Add all the ingredients to the slow cooker at the same time and cook on low for about 8 hours or until tender. Cooking time may vary depending on the size of the roast.
More Great Grilling Sandwiches
- Grilled Italian Meatloaf Sandwiches
- Jumbo Lump Crab Burgers
- Beef Short Rib Sandwich with Melted Pimento Cheese
- Habanero Cheddar Cheesesteaks
Smoked Beef Chuck Roast Sandwich
Equipment
- Pellet Grill
- Aluminum foil
- 9x13 Foil Pan
Ingredients
- 4 lb Chuck Roast
- 3 tbsp BBQ Dry Rub
- ¾ Cup Ketchup
- ½ cup Beef Broth
- 12 oz Beer
- ¼ cup Brown sugar
- 3 tbsp Honey
- 2 tbsp Soy Sauce
- 3 tbsp Worcestershire sauce
- 2 Yellow Onions Sliced
- 3 Bell Peppers Multi-colored (Sliced)
- 4 Jalapeno Peppers Sliced
- 8 Garlic Cloves about 3 tbsp Chopped
Instructions
- Preheat the Smoker to 275 Degrees F. Season the chuck roast on all sides with BBQ dry rub. Place the seasoned beef on the grates and smoke for 3 hours
- Chop and slice your garlic, onions, bell peppers, and jalapenos. Set out your other ingredients and your 9x13 foil pan.
- Place the veggies and the other remaining ingredients in the Foil pan along with the beef chuck roast, and cover with aluminum foil. Cook for another 3 hours covered.
- Pull back a corner of the foil and probe the chuck roast to see if it's tender. The probe should go into the meat with no resistance. The internal temperature should be around 205-210 degrees F. If the meat is not tender, cover and cook for another hour.
- Once the chuck roast is tender use a pair of tongs to shred the meat and incorporate it with the sauce and the veggies in the pan.
- Serve the shredded chuck roast in the pan, along with buns, pickles, and any other condiments you like.
SteevieG
OMG and I don't do the OMG thing... I have 2 chuckles and im doing this tomorrow. THANK YOU!!!
Jeff
Great recipe! Made it for a party, and people went back for thirds. Followed the recipe almost exactly as described. I only had a few notes worth mentioning for other people making this for their first time. First would be that I ladled a bit of the liquid from the pan after the braise. Not sure if my roasts were just exceptionally juicy, but the liquid almost filled the pan. I took out about half, and then added the BBQ recipe. I think this worked out for the best in this case, because the beef was still quite wet when complete. Also, I assumed the author's meat stalled at 165F, so that's when he moved it off to the foil pan. Large cuts of meat succumb to a temperature "stall" when they reach temps just above 150F. I smoked for a little over 3 hours, but my meat stalled at 155F. (I was doing two 4.5ish lb roasts in a Weber Smoky Mountain for reference). Once I realized they had stalled, I moved them to the pan to crutch them the rest of the way. The directions didn't mention it, but I re-inserted the temp probe into one of the roasts during the braising section because I wanted to take the roasts off when they hit about 203F. From my understanding, going past 205F just starts drying the meat out, but around 203F all the collagen starts to dissolve. It took just under 3 hours, so the directions were pretty spot on. Putting the mix back on the smoker was a great idea. Every piece of meat got a nice smokey taste to it, and the sweet BBQ sauce worked great with it. Will be making this again.
Don
Made this today and everyone loved it. I cooked it at 225 for about 10 hours and crutched it at the stall (162 for me) after 6 hours. Thanks for sharing.
scott
rarely come across a recipe that works.
this is pretty spot on
explained well and the pic. are great.
great idea with the sauce added.
very tasty!
eyeing up your others as well, great find!!
Jacob buzz
oh my god! pulled pork!!! i am in heaven! 🙂