When it comes to barbecued beef, smoked brisket is king. Except, beef chuck roast is a fantastic substitute. It is a budget-friendly alternative, and beef chuck becomes literal gold when cooked low and slow. Try our Chuck Roast on a Pellet Smoker recipe and get ready to taste some phenomenal BBQ beef.
If you’re craving a mouthwatering chuck roast, you have two options. Both methods yield a tender and flavorful beef roast, but one will produce shredded beef to create the best barbecue sandwich. If you are a visual learner, I have included a helpful video below demonstrating the foil wrap method. However, I’ll cover the butcher paper method in this recipe guide.
Chuck Roast:
Chuck roasts originate in the shoulder region of the steer and produce cuts known for their deep, rich beefiness. This area includes the chuck roast, the 7-bone chuck roast, the blade roast, the cross rib roast, and multiple steak cuts.
When people think of chuck roast, they think of pot roast. The two are synonymous and will likely remain that way. Because this cut is often braised, it’s also a great candidate for low and slow smoking.
Chuck roast on the pellet smoker ingredients:
- 1 chuck roast, about 3-4 pounds
- Binder: Yellow mustard, hot sauce, or Worcestershire sauce. Apply a thin coat of yellow mustard (or one of the other items listed) to the chuck roast to help keep the rub in place.
- Spice rub ingredients: kosher salt, black pepper, granulated garlic, granulated onion, chili powder, and allspice
- Apple cider vinegar for spritzing
- Pink butcher paper or Aluminum foil
- Beef broth, either pre-made or homemade (if wrapped in aluminum foil, see note below)
- A reliable instant-read meat thermometer or temperature probe
Wood suggestions: Hickory, cherry, or mesquite
Pink Butcher Paper vs. Aluminum Foil
If you’d like to preserve the bark and have the ability to slice your smoked chuck roast, I recommend wrapping it with pink butcher paper. However, if you plan to make shredded BBQ beef sandwiches, I suggest wrapping the chuck roast in aluminum foil with 1/3-1/2 cup beef broth. Doing this will steam and tenderize the meat.
Making chuck roast on a pellet smoker:
- Let the chuck roast sit at room temperature for 35-45 minutes before placing it into your grill or smoker.
- Preheat your pellet grill to 250 degrees F.
- Apply a thin coat of mustard (or hot sauce) to both sides of the chuck roast.
- Combine dry rub ingredients and apply evenly to the roast.
- Place onto your grill, close the lid, and cook for 2 hours.
- After this time, you will notice a nice bark forming on the meat. You will also notice some dry spots. That means it’s time to spritz with a little liquid.
- Combine 1/4 cup apple cider vinegar with 1/4 cup water. Place it into a clean spray bottle and spray (mist or spritz) the meat. Do this every 30 minutes until it is time to wrap.
Wrapping
- Butcher Paper option: Once the chuck roast reaches an internal temperature of 165 degrees F, it’s time to wrap it.
- Remove the roast from the grill and place it onto a large piece of pink butcher paper.
- Increase your grill temperature to 300 degrees F.
- Wrap the roast and return to your pellet grill for another 2 hours or until it reaches an internal temperature of 200 degrees F.
- Aluminum foil/steaming option: Heat beef broth before wrapping. Do not add cold or room temperature broth to the chuck roast. The broth should be the same temperature as the roast. The object is to maintain the temperature of the chuck roast, not reduce it. Heat the broth on your stovetop, side burner, or microwave.
- Tear off a large sheet of foil, place roast in the center, and curve the sides upward. Slowly pour 1/2 cup broth around the edges of the chuck roast. Carefully, finish wrapping and place it back into your pellet grill for another 2 hours or until it is done.
- Once cooked, remove your wrapped chuck roast from the grill.
- Do not unwrap it. Instead, insulate it in clean kitchen towels and let the meat rest for 1 hour before carving or shredding it.
- If your gathering is several hours away and your chuck roast is done, follow the preceding steps, and place it in a clean cooler to keep warm.
- Before serving, unwrap the chuck roast, slice (or shred), and serve.
Smoked Chuck Roast leftovers
- Store your leftover chuck roast in an airtight container in the refrigerator for up to 4 days. Place into a vacuum-sealed bag and store in your freezer for up to 3 months.
- Use the leftovers in tacos, soups, stews, and nachos!
- This smoked chuck roast recipe serves 6 people, so plan on doubling or tripling the recipe if feeding a large crowd.
Sides & BBQ Sauce:
Need some sauce and side dish suggestions for this smoked chuck roast? We’ve got you!
- Top 10 Tomato-Based Barbecue Sauces
- Air Fryer Sweet Potato Fries
- Texas Creamed Corn
- Maple Butter Grilled Corn on the Cob
- Hawaiian Potato Salad
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Chuck Roast on a Pellet Smoker
Equipment
- Pellet Grill
Ingredients
- 1 chuck roast about 3 to 4 pounds
- 1 1/2 tablespoons yellow mustard or hot sauce
- Pink Butcher paper or aluminum foil
- 1/4 cup apple cider vinegar for spritzing
- 1/2 cup beef broth for aluminum foil option
Rub:
- 1 1/2 tablespoons kosher salt
- 1/2 tablespoon black pepper
- 1/2 tablespoon granulated garlic
- 1/2 tablespoon granulated onion
- 1/2 tablespoon chili powder
- 1/4 teaspoon allspice
Instructions
- Let the chuck roast sit at room temperature for 35-45 minutes before placing it into your grill or smoker.
- Preheat your pellet grill to 250 degrees F.
- Apply a thin coat of mustard (or hot sauce) to both sides of the chuck roast.
- Combine rub ingredients and apply evenly to the roast.
- Place onto your grill, close the lid, and cook for 2 hours.
- After this time, you will notice a nice bark forming on the meat. You will also notice some dry spots. That means it’s time to spritz with a little liquid.
- Combine 1/4 cup apple cider vinegar with 1/4cup water. Place it into a clean spray bottle and spray (mist or spritz) the meat. Do this every 30 minutes until it is time to wrap.
- Butcher Paper option: Once the meat reaches an internal temperature of 165 degrees F, it's time to wrap it.
- Remove the roast from the grill and place it onto a large piece of pink butcher paper.
- Increase your grill temperature to 300 degrees F.
- Wrap the roast and return to your pellet grill for another 2 hours or until it reaches an internal temperature of 200 degrees F.
- Aluminum foil/steaming option: Heat beef broth before wrapping. Do not add cold or room temperature broth to the chuck roast. The broth should be the same temperature as the roast. The object is to maintain the temperature of the chuck roast, not reduce it. Heat the broth on your stovetop, side burner, or microwave.
- Tear off a large sheet of foil, place roast in the center, and curve the foil’s sides upward. Slowly pour 1/2 cup broth around the edges of the chuck roast. Carefully, finish wrapping and place it back into your pellet grill for another 2 hours or until it reaches doneness.
- Once cooked, remove your chuck roast from the grill. Wrap it in towels and let the meat rest for 1 hour before carving or shredding it.
- If your gathering is several hours away and your chuck roast is done, with thick kitchen towels and place it in a clean cooler to keep warm.
- Before serving, unwrap it, slice or shred, and serve.
Notes
Nutrition
Try some of our other pellet grill recipes:
- Pellet Cooked New York Strip Steaks
- Pellet Grilled Old Bay Chicken Wings
- The Best Pellet Grill Burger
- Pellet Smoked Beef Tri-Tip
- Pellet Roasted Leg of Lamb
- Holiday Rib Roast on a Pellet Grill
- Pellet Cowboy Steak
- Pellet Grill Pork Ribs
Need a Pellet Grill?
If you want to make the best pellet grill burger, you are going to need a pellet grill. Chances are if you are looking at this recipe, you already have one, but in case you don’t, you might want to check out my list of the best pellet grills on the market. I have broken them down by price, so you can find something that fits your wallet. There are more than a hundred models out there these days, so I thought you might appreciate a little help in your search.
Check out my lists of the Best Pellet Grills
7 responses to “Chuck Roast on a Pellet Smoker”
What about for a 2 pound roast?
Amy,
This would basically cut the recipe in half. The time however, will be around 4 hours. Remember that we cook to temperature not time, so leave a little space either way to get it cooked right.
During the first 2 hours on the pellet grill, does the meat need to be flipped halfway through?
Richard,
You can. The only reason to do so is if the bottom of the roast seems to be drying out or cooking too quickly. In that case, flip it over for a more even cook.
Seriously the best chuck roast I’ve ever made. Bought one at a meat sale, with it being summer I wanted to try something on the smoker. My whole family loved it and wants me to always cook it this way.
Did you use the butcher paper option or aluminum foil option?
Karie,
We us the butcher paper option with most beef. It prevents steaming and helps maintain a better surface on the roast.