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How to Smoke Pulled Pork on a Pit Boss Pellet Grill

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

This is an easy, yet really fun dish to prepare to feed a crowd, especially on a Pit Boss, but it can also easily be adapted for ANY pellet grill.

pork shoulder smoking on a pit boss pellet grill

 

Pork Shoulder, Boston Butt, or Pulled Pork?

A Boston butt, better known as a pork butt or pork shoulder, is a pork cut that comes from the upper shoulder of the pig, and is most commonly used to make pulled pork.

a raw pork shoulder before going in the Pit Boss pellet grill

The confusing name comes from the barrels in which they were transported during the 18th century, known as butts (from the Latin “buttis” meaning barrel or casket).

They were actually considered cheap cuts of meat and stuffed into barrels for easy bulk transportation.

Nowadays, pulled pork from Boston butts can be found not only in traditional American bbq, but all around the world.

You will find pulled pork in dishes ranging from Mexican carnitas, to Latino lechón asado and Chinese char siu.

 

Smoking Pulled Pork on a Pit Boss Pellet Grill

The pork shoulder is a cut of meat that provides a variety of options, and for our purposes, is quite easy to smoke, especially on a Pit Boss pellet grill

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 good overview on how to use your Pit Boss for the first time, check those articles out first!

a pit boss pellet grill smoking

 

In this article, we will go over what is needed to properly smoke pulled pork step by step in a Pit Boss pellet grill.

 

Choosing the Best Size Pork Butt for Smoking Pulled Pork on a Pit Boss Pellet Grill

Depending on the Pit Boss model you are using, and whether you will need the second shelf available for a side dish like smoked sweet potatoes or asparagus, you will need to think about what size pork shoulder you need for your Pit Boss pulled pork.

a pork butt getting placed on a pit boss to start cooking

 

Make sure to not only consider the grilling area of the Pit Boss, but the height available under the second rack if you can’t simply remove it.

Also, contrary to popular opinion in some BBQ circles, bigger ISN’T always better.

Think about it.

The larger the pork shoulder, the longer it takes to cook, and the less surface area you have relative to interior meat after you pull it.

And the surface is where the rub and all the flavor is!

In many cases, you are better off smoking (2) 4-6 lb pork shoulders for pulled pork rather than one monster 8-12 lb one.

You get done cooking that much faster, which means less time for the meat to risk drying out, and you have more crusty barky surface area mixed in with the rest of your meat!

The smoke from your wood pellets will also only penetrate about an inch into your meat, so if you want maximum smokey flavor, you are better off with multiple smaller cuts too.

Additionally, if you want to try 2 different rubs or flavor profiles, you have that opportunity as well!

IF… you can only find monster 10-14 pounders, go ahead and get one and just cut in half when you get home!

 

 

Preparing the Pork Shoulder for Smoking

You can think of the process of smoking pulled pork split into two parts.

  1. The first part is preparing your meat for the Pit Boss pellet grill.
  2. The second part is setting up and smoking the meat and then pulling it when it is done

You have literally a million options for seasoning and preparing your pulled pork 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 or maybe something asian inspired.

 

Trimming the Fat

First, you will want to trim any excess fat off the pork shoulder before applying your rub.

This will help the rub stick to and penetrate the meat itself rather than being obstructed by the fat.

a trimmed boston butt for smoking pulled pork

Leaving a little fat is ok.

You’ll notice one side will 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 1/4 inch of thickness.

After trimming, score through the fat cap with a good meat cutting 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.

If you’ve followed us for any amount of time you know we LOVE the meat melting knives from Imarku.

 

Rubs

Like we said, you can have fun finding any new and innovative rub you would like to use.

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

Because we are going to set the Pit Boss pellet grill to only 225°F, you don’t need to worry about the sugar burning.

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

 

applying mustard to a pork butt

Yes, you read that right, many professional barbecue chefs use yellow mustard to help their rub emulsify and stick to the meat when preparing pork butts, brisket, or even baby back ribs.

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 pork butt in plastic wrap and put it back in the refrigerator until you are ready to smoke it.

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.

seasoning a pork butt

 

We have a simple recipe below for a good pork bbq rub, or, if you prefer to buy your own, you know we are big fans of Blues Hog Dry Rub Seasoning.

 

Marinade Injections

For additional flavor, some bbq cooks like to inject their pork shoulder with a marinade before putting it on the Pit Boss.

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

There Is nothing wrong with injecting, and we LOVE to injected SLICED meats like smoked roast beef, ham, and turkey.

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

By adding 8 oz of injection you may be increasing your pulled pork cooking time by 1 HOUR or more.

And think about it, when the pork butt comes out of the Pit Boss pellet smoker, you are going to be pulling it apart in a big tray, and adding more 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 meat like Pit Boss smoked pulled pork, skip the hassle and add your seasoning at the end!

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

You can use a mixture of apple juice, apple cider vinegar, salt, sugar, and some of your favorite BBQ rub mixed together.

 

The Best Wood Pellets for Smoking Pulled Pork on a Pit Boss Pellet Grill

pellets in a pit boss pellet grill hopper

You have a lot of options when it comes to choosing the right wood pellets to smoke your pulled pork on a Pit Boss pellet grill.

In fact, we went DEEP in depth on our favorite smoking woods for pulled pork HERE if you want to read more on the topic.

Most smoking wood pellets are fair game to some degree, however, mesquite will give a very aggressive smoke flavor to the pork, usually a little too much if used solely on its own rather than mixed in lightly with a milder fruitwood.

Save the mesquite for quicker smoking sessions on your steaks, lobster, and even smoked crab legs where it doesn’t have time to overpower the protein.

Pecan, hickory, apple, beech, alder, and cherry pellets all give great results on pulled pork when smoked on a Pit Boss.

For a very straightforward flavor, we are also 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.

 

How a Pit Boss Pellet Grill Works

a pit boss pellet grill making smoke and cooking

In order to cook ANYTHING well on a Pit Boss pellet grill, you need to first have a basic understanding of how a pellet grill works.

***Completely New to Using a Pellet Grill?  No Worries!****

Hop over and check out this Complete Guide to Understanding How a Pellet Grill Works  if you are interested in learning more in depth.  We’ll be here when you get back!***

 

Add your Hardwood Pellets

First, you add hardwood pellets into the side hopper.

a pit boss pellet grill hopper for of pellets for pulled pork

The Pit Boss pellet grill automatically feeds these small wood pellets via an auger mechanism to a fire pot where they are burned up, providing both heat and smokey flavor.

The pellet grill automatically controls the flow of pellets depending on your temperature setting so that you maintain an even temperature throughout the entire cook.

 

How to Start up the Pit Boss Pellet Grill

  1. Fill your hopper with pellets as described above.
  2. Make sure the fire pot is cleaned out from the last cook and not full of ashes. You can remove it from the bottom and dump or vacuum it out and then put back and clip into place.a dirty pit boss pellet grill fire pot
  3. Plug in and start up the pellet grill, keeping the lid open.  Set the temperature dial to “Smoke” and press the “Power” button.a pit boss pellet grill starting up
  4. If there are no pellets in the auger or firepot yet, only in the hopper, you need to now hold the Prime” button until you hear pellets begin to drop into the firepot.using the prime button when starting a pit boss pellet grill
  5. The “Prime” feature on a Pit Boss pellet grill speeds up the auger so that pellets fill it quickly and get to your fire pot before the pellet grill “times out” from a lack of pellets coming into the fire pot.wood pellets in a pit boss pellet grill
  6. Once pellets are in the firepot, stop holding the “Prime” button and wait about 5-7 minutes with the lid open for a torchy burner lighting sound. This means the fire rod has come up to temperature and has ignited the pellets.  At this point, a more significant amount of smoke will begin coming out of the pellet grill.  This means the pellets are ignited and the pellet grill is workingNow you can close the lid. the lit fire rod in a pit boss pellet grill starting up
  7. Close the lid and change temperature setting to 350°F.  Pit Boss recommends always preheating to this temperature FIRST, even if you are eventually going to cook low and slow in the 200°-300° range.smoke coming out of a pit boss pellet grill
  8. This will take about 10-15 minutes to preheat the grill.
  9. Using a good bristle free grill brush, clean off the grill grates.long handled bristle free grill brush
  10. Now adjust the temperature to where you need it to cook your food.  In our case, drop the temperature to 225°F for the pulled pork.

 

Why Bristle Free Grill Brushes? 

Check out our Ultimate Guide to How to Keep your Family Safe by using ONLY Bristle Free Grill Brushes, along with a selection of some of our favorites!

 

How to Smoke Pulled Pork on a Pit Boss Pellet Grill

a boston butt smoking on a pit boss

Equipment

  • A large piece of foil to cover the meat
  • Cutting board
  • Knife
  • Wood pellets
  • Brush or spray bottle (preferably the latter)
  • Large forks or a proper pair of grilling tongs
  • Meat thermometer
  • Pit Boss pellet grill

 

Ingredients

  • 4 tablespoons of brown sugar
  • 3 tablespoons of salt
  • 3 tablespoons of paprika
  • ½ tablespoon of cayenne
  • 1 tablespoons of onion powder
  • 1 tablespoons of garlic powder
  • 2 tablespoons of ground black pepper
  • 5-8 lb pork shoulder
  • Apple juice or Cola
  • Apple cider vinegar
  • a 8-14 lb bone in pork butt

 

How Long Does it Take to Smoke Pulled Pork on a Pit Boss Pellet Grill?

At 225°F, it will take roughly 1.5 hours per lb to fully cook a bone-in pork butt.

So a 6 lb pork shoulder may take about 9 hours.

a pork butt smoking on a pit boss pellet grill with a temperature probe

Now, you can speed up the cook a little by increasing your cooking temperature to 250°F or even 275°F.  It will still be delicious, albeit maybe a little tougher around the exterior.

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, current internal temperature.

It’s like a GPS for your meat!

Anyways, back to our smoked pulled pork…

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

Don’t rush it.

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

165-180°F is a great temperature range for SLICING pork, but if you want it fall apart tender and easy to pull, leave it on until it hits 197°F.

Got it?

 

To Wrap or Not to Wrap, AKA the “Texas Crutch”

Another way to speed up your cooking time is by using a tried and tested barbecue technique known as the “Texas Crutch”.

Cool name, but don’t worry, it’s not complicated.

You see, when big pieces of meat like brisket or pork butt 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°F 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 pork butt out of the Pit Boss when it hits 150°F, and double or triple wrap it tightly in aluminum foil.

wrapping a smoked pork butt 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.

a foil wrapped pork butt being placed back in Pit Boss pellet grill

Unwrap the Boston butt and let it rest for about 20-30 minutes before pulling it.

Pro Tip: If you want to firm the bark back up before pulling, take it out of the aluminum foil at 192°F and place it back on the Pit Boss UNWRAPPED for the last 15-20 minutes until it hits 197°-203°F.

If this technique looks familiar, its because its very similar to how we firm our 3-2-1 pork ribs back up after removing them from foil too.

 

How to Pull the Pit Boss Smoked Pulled Pork

Once you’ve removed the pork butt from the Pit Boss pellet grill and you have let it rest in an aluminum pan for about 20-30 minutes, it’s time to pull that meat!

a finished Pit Boss smoked pork shoulder

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, test it for seasoning, you likely need to add some salt.

pulling smoked pulled pork from a Pit Boss pellet grill

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

You can also add a little apple cider vinegar and mix it in the give it some sweetness and acidity to balance out the fattiness.

As far as sauce, our hands down favorite sauce for smoked pulled pork is Blues Hog Tennessee Red Sauce.

It has everything: spice, acid, sweetness, and gives you that truly authentic vinegary carolina pulled pork flavor that perfectly counterbalances and cuts through the rich fat and smokiness of your Pit Boss pulled pork.

Keep in mind a little goes a long way because it has SO MUCH FLAVOR.

Pro Tip: It’s always best to offer BBQ sauce on the side and let your guests choose whether to add it and how much to add rather than slopping it all over your meat and possibly turning folks off.

You spent a lot of time on that meat so let them taste it first rather than dousing it in bbq sauce immediately!

 

Serve and Enjoy!

And there you have it!

Serve your Pit Boss smoked pulled pork on large brioche buns for an extra level of deliciousness, and you can even top it with some vinegary coleslaw and serve along with some baked beans and corn on the cob for an authentic bbq experience!

finished pulled pork cooked on a pit boss

 

What Else Can I Smoke on my Pit Boss Pellet Grill?

Looking for some more smoky inspiration for that new Pit Boss?

So glad you asked.

Check out some of our other great recipes of smoked and grilled food to try out at your next outdoor BBQ!

They can all easily be adapted to be made on a Pit Boss pellet grill.

 

More Smoked Pork

 

Poultry

 

Smoked Beef

 

Smoked Seafood

 

Smoked Lamb

 

Other Odds and Ends

 

pork shoulder smoking on a pit boss pellet grill

Pit Boss Smoked Pulled Pork

Learn exactly how to smoke pulled pork on a Pi Boss pellet grill following our detailed instructions and recipe below!
This is an easy, yet really fun dish to prepare to feed a crowd, especially on a Pit Boss!
5 from 1 vote
Prep Time 2 hrs 30 mins
Cook Time 8 hrs
Resting and Pulling Time 1 hr
Total Time 11 hrs 30 mins
Course Main Course
Cuisine American, Australian, barbecue, BBQ, Smoked
Servings 12
Calories 700 kcal

Equipment

  • Pit Boss Pellet Grill
  • Wood pellets for Pit Boss, preferably hickory, apple, and/or cherry
  • Aluminum Foil Trays
  • Plastic Wrap
  • Internal Meat Thermometer
  • Brush or spray bottle (preferably the latter)
  • Heavy Duty Aluminum Foil
  • Cutting Board
  • Knife
  • Large forks or a Pair of BBQ Bear Claws

Ingredients
  

  • 5-8 lb Pork Shoulder Bone-In. Also sometimes labeled as a Pork Shoulder or Boston Butt.
  • Olive Oil or Yellow Mustard

Mad Backyard's Pulled Pork Rub

  • 4 Tbsp Brown sugar
  • 3 Tbsp Salt
  • 3 Tbsp Paprika
  • ½ Tbsp Cayenne
  • 1 Tbsp Onion powder
  • 1 Tbsp Garlic powder
  • 2 Tbsp Ground black pepper

Additional Ingredients

  • Apple Juice or Cola in a Spray Bottle optional to spray during the cook
  • Salt to taste
  • Apple cider vinegar to taste
  • Blues Hog Tennessee Red BBQ Sauce - OR - any vinegar based BBQ sauce for pulled pork

Instructions
 

Prepare the Pork Butt for the Pit Boss

  • Trim any excess fat from the exterior of the pork butt. Trim the fat cap down to 1/4" thickness. Score the fat cap with a meat knife in 2 directions perpendicular to each other.
    a raw pork butt
  • In a bowl, mix all the dry ingredients. This includes the brown sugar, salt, paprika, cayenne, the onion and garlic powders and the ground black pepper. Mix it all to make the dry rub. Keep in mind you can always buy your own dry rub or use your own recipe. It’s up to you.
    mixing the rub ingredients for traeger smoked baby back ribs
  • Cover your boston butt with a thin layer of olive oil or yellow mustard, then generously apply your rub to coat the entire exterior of the meat.
    applying mustard to a pork butt
  • Wrap your boston butt in plastic wrap and place it back in the refrigerator for at least 2 hours, preferably overnight.
    seasoning a pork butt for pulled pork on a pit boss pellet grill

Start the Pit Boss Pellet Grill

  • Remove the fire pot from the bottom of the Pit Boss and clean out any ashes left over from the last cook. Replace it and make sure it is secured in place with the clips on either side. Also, wrap the drip tray in aluminum foil to limit cleanup needed later.
    a dirty pit boss pellet grill fire pot
  • Add your chosen pellets to the hopper, start the Pit Boss pellet grill and put it on the "Smoke" setting.
    a hopper with pellets in a pit boss pellet grill
  • If there are no pellets in the auger, hold the "Prime" button until you hear pellets begin falling in the fire pot. This will speed up the auger to prime it full of pellets before you start preheating.
    starting a pit boss pellet grill
  • Once the Pit boss begins to produce thick white smoke, let it run for about 5-7 minutes until the smoke turns more of a clearish blue color. This means the fire rod has fully heated up to burn the pellets more cleanly.
    smoke coming from a pit boss vertical smoker
  • Next, set the temperature to preheat the pellet grill to 350°F. We will drop this temperature before we start cooking.
  • Remove the top rack if you are not using it.
  • Fill an aluminum pan with water pan if you want to add extra moisture, and place it on the far left side of the Pit Boss pellet grill. Place a disposable bucket liner in the grease bucket as well if you want to limit cleanup later.
  • Once the Pit Boss has come up to 350°F, drop the temperature on the control panel to 225° and clean the grill grates with a good grill brush and close the lid.

Start Smoking the Pork on the Pit Boss

  • Remove the pork from the refrigerator, add any additional rub that may have come off, and once the Pit Boss is at 225°F, place the pork butt on the grate with the fat side DOWN and the thickest part facing to the hotter RIGHT side.
    a pork butt getting placed on a pit boss to start cooking
  • Place your thermometer inside the pork making sure to not touch the bone.
  • Set a timer to 3 hours and close the lid to the Pit Boss. Every hour you can optionally spray or baste the exterior of the meat with apple juice or cola to help form the bark and keep the meat moist.
    basting apple juice on to a pork shoulder vor pulled pork on a pit boss
  • Your meat will take on average 1.5 hours total to cook per pound. You can refill more wood pellets as needed, however, with a full hopper you should not need to add much more.

Texas Crutch

  • When the internal temperature of the pork butt hits about 150-155°F, remove it from the Pit Boss and triple wrap it in aluminum foil. Replace the thermometer and place back in the pellet grill.
    a wrapped pork butt in foil on a pit boss grill
  • Once the internal temperature hits 192°F, remove the pork from the foil and place it unwrapped back in the Pit Boss to firm the bark back up. You can increase the temperature up to 275°F at this time if you wish.
  • Once the internal temperature hits 197°-203°F, remove the pork butt from the Pit Boss and place it in an aluminum pan. Let it rest fo 20-30 minutes.
    a pork butt smoking on a pit boss pellet grill

Pull and Serve the Pit Boss Smoked Pulled Pork

  • Pull your pork using a pair or forks or Bear Claws. Discard any large pieces of fat and the bone.
    finished pulled pork cooked on a pit boss
  • After you finish pulling and mixing, taste the pulled pork and add salt to taste, mixing as you add it in. You can also add some apple cider vinegar to taste to add some acidity.
  • Serve with buns and a vinegar based BBQ sauce on the side to top with like Blues Hog Tennessee Red.

Video

Notes

Video courtesy of Dutch Eats.
Keyword barbecue, bbq, BBQ Rub, Boston Butt, budget, Grilling, hickory, How to, pellet grill, pellet grills, pellet smoked, pellet smoker, Pit Boss, Pit Boss Boston Butt, Pit Boss Pork Butt, Pit Boss Pork Shoulder, Pit Boss Pulled Pork, pork, Pork Butt, Pork Shoulder, Pulled Pork, smoked pork, Smoking, Wood pellets, wood smoke

One Comment

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  1. 5 stars
    This came out great! Thanks for the step by step instructions for us “old guys”. :-). Will have to check out that Blues Hog Sauce for the next one

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