Pellet Grill Pork Butt

Smoked Pork Butt vs. Smoked Pork Shoulder

This is a big question I get about pellet grill pork butt. Which cut of meat should you use? It’s a little confusing, but let me break it down.

Pork butt and shoulder are almost the same cut. While they come from slightly different areas of the pork shoulder, you can use them interchangeably for this recipe. And you could even use Boston butt, which is another (usually smaller) cut also from the shoulder region.

Recipe Ingredients

Can you believe how simple the ingredients are?

• Pork Butt – Aim for a whole bone-in, skinless pork butt or pork shoulder weighing 8-12 pounds.
• Pork Rub – Make your own tasty pork rub with black pepper, onion powder, garlic powder, dried oregano and thyme, cumin, brown sugar, chili powder, cayenne, and paprika. Add salt to taste.

How to Smoke Pork Butt on a Pellet Grill

Season the Pork Butt

1. Make the Dry Rub – Mix the salt, pepper, garlic and onion powder, thyme, oregano, brown sugar, chili powder, cayenne pepper, smoked paprika, and cumin in a medium bowl until completely combined. Set aside. 
2. Trim – Next, place the pork butt on a large cutting board, fat cap side up. Trim the pork, if needed, leaving a narrow layer of fat (about ⅛”‒¼” inch thick) on the outside to keep the pork from drying out. Then, dry the roast with paper towels. 
3. Season – Optionally, slather a thin, even coating of yellow mustard or Worcestershire sauce on all sides of the pork to bind the seasonings to the pork. Next, salt the pork and rub the entire surface of the meat with seasonings, pressing it down as season until every inch is covered. (Photo 1)
4. Marinate – Tightly cover the seasoned pork butt in an aluminum foil pan and let it rest for at least an hour or up to 24 hours. (Photo 2)

Smoke It

1. Room Temp – Remove the pork from the fridge about an hour before smoking if time permits. 
2. Smoke – Fill the pellet grill hopper with wood pellets and preheat the grill to 250-275°F (120-135℃). Or prepare your charcoal grill for indirect grilling and preheat it to 250-275°F (120-135℃). Add hardwood chunks to the charcoal to create more smoke. Next, place the pork butt directly on the grill grates, fat side up, and insert an instant-read grill thermometer. (Photo 3)
3. Wrap – Once the pork reaches 165℉ (75℃), take it out of the smoker and wrap it tightly with butcher paper or foil. Alternatively, place it in an aluminum foil pan and cover it tightly. At this point, you can add additional pork rub, hot sauce, or any optional seasonings. (Photo 4)
4. Slow Cook – Put the wrapped pork back in the smoker and smoke it until the internal temperature reaches around 205°F (95℃), or the pork easily shreds with a fork.
5. Serve – Remove the pork butt from the smoker and let it rest at room temperature for 45 minutes to an hour. Shred and serve as desired.

Recipe Variations

Smoked pork butt is as versatile as it is delicious. Try some of these ideas for a super easy weeknight dinner or crowd-pleasing cookout surprise.💡

• Marinade Upgrade: Marinate the pork butt overnight. Pineapple juice, olive oil, ground ginger, soy sauce, black pepper, garlic powder, and pepper flakes deliver a tropical flair. While red wine vinegar, Dijon mustard, maple syrup, and olive oil take it to the country. Olive oil, apple cider vinegar, Italian seasonings, garlic, onion powder, and smoked paprika is a fantastic marinade.
• Inject Taste: Consider using a meat injection to add flavor and moisture to the interior of the pork butt. Injecting marinades can infuse the meat with extra flavor. If it works for turkey, why not pork?
• Fruity Twist: Add fruit juices or sauces in your marinade or as a basting liquid during the smoking process. Apple juice, pineapple juice, or peach glaze can enhance flavor. 🍑
• Oven-Roasted Pork Butt: Add half a teaspoon of liquid smoke to your marinade for the smoke flavor. Then, put the roast in a preheated 450℉ (230℃) oven for 30 minutes to get a crust. Lower the temperature to 250℉ (120℃) and slow roast it for about 7 hours (internal temperature should read 180℉/80℃).
• Smoked Pork Butt Chili: Chop the smoked pork butt into bite-sized pieces and add it to your favorite chili recipe.
• Cuban Sandwich: Use sliced smoked pork butt as a filling for a traditional Cuban sandwich with ham, Swiss cheese, mustard, and pickles.
• Pork Fried Rice: Chop it into little pieces and throw it into your favorite fried rice recipe for a delicious twist on this eternal classic.
• Smoked Pork Butt Mac and Cheese: Stir shredded smoked pork butt into your favorite mac and cheese recipe for a hearty meal.

We haven’t even gotten into pulled pork sandwiches, tacos, and sliders. So feel free to experiment and invent your own variations!

Tips and Tricks

• If you use a charcoal grill to smoke the pork butt, soak your wood chunks in water for about 30 minutes before adding them to create a steady stream of smoke.
• Smoking pork butt takes time, usually around 1½-2 hours per pound. Calculate the cooking time and plan accordingly, including time for prepping and resting. The wait is so worth it.
• Be ready for the stall. Pork butts heat up to about 145℉ (62℃) rather quickly, and then it can seem to take forever to reach 165℉/73℃. But don’t panic. They call this phenomenon the stall for a reason, and it’s totally normal.

Make-Ahead Instructions

This is a great make-ahead dish. Make it a few days before and store it in the fridge in an airtight container. You can even freeze smoked pork butt for 3-4 months if you’d like. Just keep it in a freezer-safe container and thaw it in the fridge the night before serving it. 

If you want to take advantage of a super good pork roast sale, you can season and freeze the meat for up to three months. Thaw it in the fridge overnight, let it set at room temperature for 30 minutes to an hour, and then smoke your pork butt.

Serving and Storage Instructions

As soon as it has finished resting, serve smoked pork butt with all your favorite BBQ side dishes. You may be able to slice the meat, but it will likely be so tender that shredding is your best option for serving it up. That makes it the perfect filling for pulled pork tacos and sliders.

Keep leftovers in the fridge for 3-5 days. You can reheat pork in a skillet on the stovetop, a pan in the oven, or pop it in the microwave. Keep temperatures at medium-low in or on the stove just until the meat is heated through.

FAQs

Why should I bring the roast to room temperature before smoking?

Don’t panic because an hour at room temperature isn’t enough time to ruin anything. In fact, just the opposite. It ensures a juicier roast because cold meat can’t sear as well. And related to that, your roast won’t shrink as much because the sear maintains the juices inside.

Something I hadn’t thought of is reducing refrigerator aroma by letting it air out an hour before cooking. And it cooks more evenly because the center of the roast doesn’t have as far to go to reach the correct internal temperature.

And totally beside the point, letting it rest for 10-15 minutes before slicing allows the muscle fibers to relax, and the juices reabsorb into the meat for better results.

What’s the best type of wood pellets to use for smoking pork butt? 

The choice of wood pellets can influence the flavor of your smoked pork butt. Common options include hickory, apple, cherry, maple, pecan, and mesquite. Each type imparts a distinct smoky flavor, so choose one that complements your taste preferences. 🪵

Do I need to let the pork butt rest after smoking? 

Yes, it’s essential to let the smoked pork roast rest for at least 30 minutes after removing it from the grill. That allows the juices to redistribute within the meat for a juicier, more flavorful final product.

What’s the best way to shred or pull smoked pork butt? 

After the pork butt has rested, use two forks to shred or “pull” the meat apart. The tender, smoked meat should easily separate into succulent strands. Or you can use meat claws for faster shredding.

What Goes With Pellet Grilled Pork Butt

Serve it with grilled bread, coleslaw, smoked baked beans, and other classic BBQ sides you love. Don’t forget to offer your guests plenty of homemade BBQ sauce, like this insanely good honey BBQ sauce. 🤤

More Savory Pellet Smoker Recipes to Try

• Sweet Smoked Pineapple
• Smoked Beef Tenderloin
• Savory Smoked Meatballs
• Pellet Grilled Lobster Tail
• Tri-Tip Sandwich

Conclusion

This melt-in-your-mouth, smoky BBQ classic will surely have everyone coming back for seconds. Are you a seasoned pitmaster when it comes to making pellet grilled pork butt? If so, drop your best tips in the comment section below!