Smoked Chuck Roast on a Pit Boss Pellet Grill

Learn how to smoke a chuck roast on a Pit Boss pellet grill following our detailed instructions and recipe below!

This is an easy and affordable piece of meat to prepare to make pot roast, shredded beef for tacos, and countless other dishes.

When it comes to smoking beef, a chuck roast is a great option for beginners, or those looking to feed a crowd without breaking the bank on a prime rib roast or beef tenderloin.

You've probably seen many a chuck roast thrown into a slow cooker all day to make "pot" roast.

That's because low and slow is the BEST way to cook this very affordable cut of beef.

Only instead of braising it with liquid in a pot, today we are going to slow smoke a chuck roast on our Pit Boss pellet grill!

Jump to:

• What is a Chuck Roast?
• Bone-In or Out?
• Size
• Trimming the Fat
• Rubs
• Marinade Injections
• Wood Pellets
• Setting up the Pit Boss
• Smoking Temperature
• Cooking Time
• Final Internal Temperature
• Using the "Texas Crutch"
• Optional: Braising to Finish for Smoked Pot Roast
• How to Pull or Shred
• How to HOLD the Roast on the Pit Boss
• Storing and Reheating
• 📖 Recipe

What is a Chuck Roast?

Much like a pork shoulder, or Boston butt, on a hog, a chuck roast is meat cut from the shoulder muscles of a steer, making it one of the best options for smoking pulled beef. (Or shredded beef, depending on which term you prefer).

The seasoning is usually straightforward, as a simple dry rub can bring out all the flavors in the meat, and then a nice long smokey cook on the Pit Boss pellet grill will tenderize it.

After a whole day of cooking, one good sized chuck roast will definitely feed a crowd.

You can shred it to make sandwiches, tacos, fajitas, or even serve it like pot roast alongside some traditional carrots and potatoes.

Bone-In or Out?

You could go with the full chuck slab that looks similar to a brisket, or you can look for the blade cut version without the bone.

The bone can add flavor. But it will also increase the time it takes cook.

If you DO get a bone-in chuck roast, there is no need to remove the bone before cooking.

It will slide out cleanly and easily after the chuck roast has been smoked, much in the same way one does on a perfectly smoked pork shoulder.

Size

The size of the chuck roast you choose to smoke on your Pit Boss depends on how many people you want to feed, but also on the time you want to spend smoking the meat.

A 3-4 pound chuck roast will take around 7-8 hours to smoke on a Pit Boss at 250°F and will feed about 7-9 people.

So yes, smoking a chuck roast on your Pit Boss can take all day.

There is also nothing wrong with smoking it the day before you serve it.

Smoked chuck roast will reheat wonderfully in the oven in an aluminum pan covered with aluminum foil.

You can even add a little beef broth to the pan to bring it back to life and infuse some additional moisture.

This way you can enjoy visiting with your guests rather than tending to the smoker on the day of your gathering.

 

Trimming the Fat

You can think of the process of smoking a chuck roast on the Pit Boss split into three parts.

1. The first part is preparing and seasoning the chuck roast
2. The second part is setting up and smoking the meat on the Pit Boss
3. The final part is resting, and then pulling or shredding it and incorporating it into whatever dish you are using it in.

Leaving a little exterior fat is ok.  You are smoking the chuck roast long enough that most of it will render away.

Depending how it was butchered and packaged, you'll notice one side may have a thicker "Fat Cap" on it.

It's OK to leave some of this in place but ideally trim it down to no more than about ¼ inch of thickness.

After trimming, score through the fat cap with a good knife in 2 perpendicular directions to help the fat underneath render out during the smoking process and allow some more of the rub to penetrate the meat.

Rubs

You have lots of options for seasoning and preparing your Pit Boss chuck roast depending on the flavor profile you are going after.

You can use anything from a traditional American BBQ rub to something more exotic or internationally flavored such as a spicy chipotle rub for fajitas.

Maybe something more Asian inspired for stuffing dumplings or serving with lo mein?

Conventional American BBQ rubs have A LOT of sugar in them as that is what helps form the crusty bark on the exterior of ribs or a pork shoulder as it cooks in the smoker.

Because we are going to set our Pit Boss to only 225-250°F, you don't need to worry about any sugar burning at those "low and slow" temperatures.

However, unlike pork, which pairs well with sugary BBQ rubs, beef is usually better suited for more straightforward salt and pepper style seasoning.

You can add a little cayenne for extra heat or garlic and onion powder for additional flavor, but go easy on the rubs that are heavy in sugar content.

We are big fans of Bad Byron's Butt Rub Seasoning on smoked beef, especially brisket and chuck roast because it is heavy on flavor, and has no sugar.

It also works great anytime you are cooking something like our hot and fast brisket or a whole chicken, and you don't want a sugary rub to burn at those higher smoking temperatures.

After trimming the fat, cover the chuck roast in a thin layer of cooking oil or yellow mustard.

Yes, you read that right.

Many professional barbecue chefs use yellow mustard to help their rub emulsify and stick to the meat.

After the long cook you won't taste any mustard flavor, trust us.

Be generous with the amount of rub you put on.

Then you can wrap the chuck roast in plastic wrap and put it back in the refrigerator until you are ready to start up the Pit Boss.

This can even be done the night before to save some time the next day and to let the salt in the rub fully penetrate the meat.

Marinade Injections

For additional flavor, some bbq cooks like to inject their chuck roast with a marinade before putting it in the smoker.

The idea is to add flavor and moisture deep into the meat to help season the bland interior of the beef while its cooking.

There is nothing wrong with injecting, and we LOVE to injected SLICED meats like smoked brisket, ham, and turkey.

The only problem is it adds water weight and significantly extra time to your cook.

By adding 8 oz of injection to your smoked chuck roast you may be increasing your cooking time by an hour or even more.

And think about it, when the chuck roast comes off of the Pit Boss, you are going to be pulling it apart in a big tray, and adding seasoning at that point too.

So why go through the hassle of injecting the interior if you are going to be adding seasoning later anyways?

Injections work great on sliced meats like the ones mentioned above because you are slicing and serving and wanting the slices of meat to have flavor all the way through.

But with pulled or shredded beef meat like smoked chuck roast, skip the hassle and add your seasoning at the end.

However,

If you REALLY want to inject your smoked chuck roast or any other type of meat, always use a good quality meat injector like this one from JY COOKMENT.

For chuck roast we recommend a blend of beef broth, worcestershire or soy sauce depending on the style you are going for, and a little but of Bad Byron's Butt Rub mixed in as well.

Wood Pellets

You have a lot of freedom when it comes to choosing the right wood pellets to smoke your Pit Boss smoked chuck roast.

Mesquite and hickory will give a very aggressive smoke flavor, so should mixed with milder wood pellets so as not to overdo it.

Alternatively, you can also go for an overall milder smoke flavor by choosing oak or fruitwood pellets.

Pecan, apple, beech, alder, and cherry all give great results on smoked chuck roast.

For a straightforward smoke right out of the bag, we are big fans of Bear Mountain Red and White Smoky Oak Pellets

For the best results, store your unused pellets in a sealed room temperature container like this 20 lb pellet container rather than in the Pit Boss hopper outside.

Pellets do not last forever, but will definitely last a LOT longer if stored indoors in a quality airtight container.

Setting up the Pit Boss

We have previously covered how to season a Pit Boss, how to start a Pit Boss, as well as how to troubleshoot the smoke level of your pellet grill.

So if you need a more in-depth review on how to use your Pit Boss for the first time, check those articles out first!

Smoking Temperature

After going through the startup process described above, set the temperature to 250°F, and let the Pit Boss come up to temperature.

We Are going to cook the chuck roast low and slow to high final temperature, similar to a beef brisket, rather than cooking it to a certain doneness like a prime rib or a good cut of steak.

This is because chuck roast has more fat and connective tissue that needs to break down, and it will taste better cooked in this way.

 

Cooking Time

At 250°F, it will take roughly 1.5-2 hours per lb to fully cook a chuck roast to the point where you can pull or shred it.

So a 3-4 lb chuck roast may take anywhere from 6-8 hours.

This will vary based on outdoor temperature, humidity, the fat content of the chuck roast you purchased and whether or not is is bone-in or boneless.

Make sure to use a good temperature probe to keep track of your meat's temperature while it is cooking.

We are big fans of this one from ThermoPro.

While we have used and recommended ThermoPro for years, lately we have also become big fans of the MEATER leave in thermometer.

It is extremely accurate and has an incredible 165 foot bluetooth range and works right with your smartphone so you don't need to carry a separate controller around with you like many other remote thermometers require.

It's got a great free app that is constantly being updated and even has an algorithm to predict how much longer your type of meat will take to cook based on cooking temperature, target temperature, and current internal temperature.

It's like a GPS for your meat!

Anyways, back to our smoked chuck roast...

Final Internal Temperature

You are going to leave your chuck roast on the Pit Boss until it hits somewhere between 197-203°F when measured with a good temperature probe or instant thermometer.

Don't rush it!

Chuck roast is not a cut of meat you want to serve medium or even medium well like a nice ribeye roast.

There is too much intramuscular fat and connective tissue that needs to break down and render at higher temperatures.

The chuck roast will be tough and unappetizing if you cook and serve it like a tenderloin or prime rib roast.

Smoked chuck roast is best served when cooked to 200°F internally, then allowed to rest, and then pulled or shredded.

It will not be fall apart tender or pull well even if you take it off the Pit Boss at 180°F.

 

Using the "Texas Crutch"

One way to speed up your cooking time and increase the tenderness of your Pit Boss smoked chuck roast is by using a tried and tested barbecue technique known as the "Texas Crutch".

Don't worry, it's not complicated.

You see, when big pieces of meat like brisket or pork shoulder are being cooked low and slow, and hit about 150°F internally, they tend to "stall out" and stop rising in temperature.

Sometimes for hours depending on the size of the meat.

This can be maddening if your guests are arriving soon and the internal temperature needs to rise another 50° and hasn't budged for over an hour!

Without getting too much into the science behind why this happens, just understand it has to do with a lot of trapped moisture evaporating at this temperature and continually cooling your meat as it evaporates.

One way to "power through the stall" is to take your chuck roast off of the Pit Boss when it hits 150°F, and double or triple wrap it tightly in aluminum foil.

Then replace your thermometer, place the meat back on the Pit Boss, and let it continue to cook.

The aluminum foil will keep the moisture from evaporating, possibly keeping your meat from drying out as much while to cooks, and most importantly, let it continue to steadily rise in temperature.

Leave it wrapped until it gets to your target temperature range of 197°-203°F and then remove it from the smoker.

Unwrap the chuck roast and let it rest for about 20-30 minutes before pulling or shredding it.

 

Optional: Braising to Finish for Smoked Pot Roast

Love Pot Roast?

Us too.

Want to make it on your Pit Boss?

Cool.  Here's what you do:

Smoke your chuck roast directly on the Pit Boss for the first 3 hours or so as described above until it hits around 150°F internally.

Now, instead of wrapping directly in aluminum foil as with the Texas Crutch, place it in an aluminum pan and add about 3-4 cups of good quality beef stock into the pan.

Make sure the liquid comes about ⅓ to ½ way up the sides of your chuck roast.

You are also welcome to add some sliced onions and carrots, or anything else you want.

If you are going for Mexican flavors, maybe toss in a couple of seeded jalapenos.

For more Asian flavors, add some soy sauce and a little rice wine vinegar.

Then tightly cover the top of the pan with aluminum foil and place it back on the Traeger.

You can still run your temperature probe underneath the foil and into the chuck roast to keep an eye on the internal temperature.

Don't just peirce the top of the foil though or all that good tenderizing steam will escape and kind of defeat the purpose.

 

How to Pull or Shred

Whether you used the Texas Crutch or the Pot Roast method, you need to let the chuck roast after it comes up to temperature

Once you've removed the smoked chuck roast from the Pit Boss and have let it rest for about 20-30 minutes, it's time to pull that meat!

You can use 2 forks or, better yet, a pair of BBQ Bear Claws to make the job even faster (and fun)!

Once you have pulled the meat, taste test it for seasoning, you likely need to add some more salt, beef stock, or some more Bad Byron's Butt Rub.

Add a little salt at time, mixing it in and re-taste testing as you go.

 

How to HOLD the Roast on the Pit Boss

What do you do if you finish your smoked chuck roast well before your guests arrive?

If you hit that magic 200°F temperature internally early in the day or evening, drop the temperature  on your Pit Boss down to 180°F.

Then leave the chuck roast lightly wrapped in aluminum foil so it doesn't dry out, and close the lid.

This works great in an oven too depending how long you are waiting and if you want to save your expensive pellets.

Anything above 170°F will keep the meat at a food safe temperature (unlike leaving it sitting out on the counter...don't do that) while also keeping it hot.

If you keep the lid closed and/or the pan covered with aluminum foil, it will stay plenty moist as well.

You can hold the meat here for several hours if you need to until your guests arrive, and you may find it shreds and tastes EVEN BETTER after doing so.

Pro Tip: Hold the meat at this temperature in its WHOLE form rather than shredding if you can, then shred and season immediately before serving for maximum tenderness and moistness.

 

Storing and Reheating

If you are saving your Pit Boss smoked and shredded chuck roast for a party the next day, or using the beef in a recipe that you are going to prepare at another time, then you can easily store it in the refrigerator after shredding it and letting it cool for about 20-30 minutes.

Make sure to keep it covered at all times so that it does not dry out.

When you are ready to reheat it, you can add a little additional beef stock to liven it back up and put it in the oven, covered in foil at 300°F and reheat for about 30-45 minutes depending on the amount of beef.

Stir it occasionally and check the temperature to get it the point of being piping hot without overcooking it or drying it out, somewhere around 180°F with an instant read thermometer.

 

📖 Recipe