Home » Blog » Recipes » Chuck Roast on a Pellet Smoker

Chuck Roast on a Pellet Smoker

, , , , ,

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.

Chuck Roast on a Pellet Smoker
derrickriches.coim

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.

Beef Cuts - Chuck Roast

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

Wrapping a Chuck Roast
  • 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.
Smoked Chuck Roast Sliced
  • 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!

Looking for a new pellet grill? derrickriches.com is the most trusted source for honest and reliable reviews. See our recommendations below:

Chuck Roast on a Pellet Smoker

Chuck Roast on a Pellet Smoker

Chuck roast is one of my favorite cuts of beef on the smoker. Absolutely rich and delicious. Shred and serve this Chuck Roast on a Pellet Smoker as is or in sandwiches. Dang, it’s delicious!
4.72 from 70 votes
Print Pin Rate
Course: Main Course
Cuisine: American BBQ
Keyword: bbq, smoked chuck roast
Prep Time: 15 minutes
Cook Time: 6 hours
Total Time: 6 hours 15 minutes
Servings: 6 People
Calories: 288kcal
Author: Derrick Riches

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

Pellet suggestion: Mesquite or Hickory
 
 

Nutrition

Calories: 288kcal | Carbohydrates: 3g | Protein: 30g | Fat: 18g | Saturated Fat: 8g | Trans Fat: 1g | Cholesterol: 104mg | Sodium: 2620mg | Potassium: 589mg | Fiber: 1g | Sugar: 1g | Vitamin A: 421IU | Vitamin C: 1mg | Calcium: 45mg | Iron: 4mg

Try some of our other pellet grill recipes:

Need a Pellet Grill?

Broil King Regal 400 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

Buy Our Books!


Recipes

  • Smoked Pork Tenderloin
    Elevate your BBQ game with this smoked pork tenderloin, Juicy pork, savory rub, homemade BBQ sauce. Perfect for novice cooks!
  • Homemade Greek Seasoning
    Infuse Mediterranean flavor in your grilled or smoked meats with this quick and easy homemade Greek seasoning!
  • Easy Oven Baked Ribs
    No smoker? No problem. Our comprehensive recipe guide will teach you how to make delicious ribs in the oven!
  • The Ultimate Colcannon
    The ultimate comfort food dish. This easy, homemade recipe for Irish mashed potatoes will keep you coming back for more!
  • Bacon-Wrapped Pork Tenderloin
    Juicy pork tenderloin wrapped in smoky bacon. With minimal ingredients, it’s easy to assemble and sure to impress.
, , , , ,

9 responses to “Chuck Roast on a Pellet Smoker”

    • 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.

  1. 5 stars
    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.

Leave a Reply

Your email address will not be published. Required fields are marked *

Recipe Rating




This site uses Akismet to reduce spam. Learn how your comment data is processed.

Smoked Chuck Roast