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Smoked Chuck Roast on a Pellet Grill

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When it comes to barbecued beef, smoked brisket reigns supreme. However, beef chuck roast is an excellent alternative. It is a budget-friendly alternative, and beef chuck becomes literal gold when cooked low and slow. Try our Smoked Chuck Roast on a Pellet Grill recipe and get ready to experience some phenomenal BBQ beef!

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If you’re in the mood for smoked chuck roast, you have two options for cooking it. Both methods result in a tender and flavorful beef roast, but one will produce shredded beef that is perfect for sandwiches, while the other will produce a more brisket-like outcome. 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

What is a chuck roast?

The chuck roast 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 a 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 (or a Texas-Style SPG)
  • 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, oak, or pecan

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 smoked chuck roast on a pellet grill

  • Let the chuck roast sit at room temperature for 35-45 minutes before placing it into your grill or smoker. This allows the meat to cook more evenly and retain its natural juices, resulting in a tender and flavorful roast.
  • 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 in a small bowl, and apply evenly to the roast.
  • Place chuck roast on the grill, close the lid, and cook for 2 hours.
  • After 2 hours, 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.
  • Make a spritz by combining 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 the chuck roast

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) on a clean cutting board, and serve with a little of the braising liquid on top.

Storing and Rewarming 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.

What to do with leftover chuck roast

Are you looking for ways to use up smoked beef chuck roast? Here are some of our favorite ways to use it.

  • Smoked Chuck Roast Tacos: Shred or chop the chuck roast and use it as a filling for delicious tacos. Add your favorite toppings like fire-roasted salsa, avocado, or chorizo queso for a Tex-Mex flair.
  • Beefy Quesadillas: Use the shredded or finely chopped smoked chuck roast to create the best quesadillas. Use a combination of sharp cheddar and pepperjack cheese, sautéed onions, and peppers for a true taste sensation!
  • Smoked Beef Sandwiches: Thinly slice the leftover chuck roast and use it in sandwiches along with Swiss, arugula, lettuce, mayo, and more. You’ll have an excellent roast beef sandwich!
  • Chuck Roast Hash: Chop up the leftover smoked chuck roast and sauté it with diced potatoes, onions, and bell peppers. Serve with over-easy eggs on top for a hearty breakfast or brunch.

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 reliable reviews. See our recommendations below:

smoked-chuck-roast-featured

Smoked Chuck Roast on a Pellet Grill

Looking for great alternative to smoked brisket? This chuck roast recipe is your best bet!
4.73 from 72 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:

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9 responses to “Smoked Chuck Roast on a Pellet Grill”

    • 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.

4.73 from 72 votes (67 ratings without comment)

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Smoked Chuck Roast