Smoked Chuck Roast for Juicy Pulled Beef

By James Kimble June 17, 2025 9 mins read 8 Views

Pulled pork might get most of the attention in barbecue, but smoked pulled beef deserves a spot on your table too. This recipe turns a humble chuck roast into tender, smoky, shredded beef perfect for sandwiches, tacos, or stuffing into baked potatoes.

Instead of slicing or cubing the chuck roast like we do in our Poor Man’s Brisket or Poor Man’s Burnt Ends, this recipe takes a different route. The chuck roast is smoked low and slow, then wrapped and braised until it’s fall-apart tender. The result is rich, saucy pulled beef that practically shreds itself.

Why you’ll love this foolproof smoked pulled beef

Beginner-friendly: Uses a simple two-step smoke, then braise for consistent results every time.
Packed with flavor: Starts with salt and pepper for bark, then finishes with sauce and sweet BBQ rub.
Budget-conscious: Chuck roast delivers rich, beefy results without the brisket price tag.
Meal prep–friendly: Shreds easily and reheats well for leftovers throughout the week.

Shredded smoked chuck roast in a foil tray, ready to serve with white bread, barbecue sauce, and sliced pickles.

This recipe is for a sweeter, more classic BBQ-style pulled beef packed with barbecue sauce. Similar to the flavor profile of a classic Texas Chopped Beef, it combines sweet and savory flavors.

Ingredients you need

Beef Roast – Use a chuck roast or shoulder roast with good marbling and connective tissue. Brisket also works if you’re cooking for a crowd.
Salt and Pepper – Keep it simple for the first part of the cook. Salt and coarse black pepper help build bark without burning. Avoid sugary rubs here. You can add a touch of garlic powder or use a salt-forward beef rub if preferred.
Butter – Salted or unsalted butter both work. Use what you have on hand.
BBQ Dry Rub – Apply this during the wrap stage. A sweeter rub adds great flavor at this point without burning. Pork rubs often work surprisingly well, thanks to their garlic, onion, and sugar blend.
Barbecue Sauce – A ketchup-based BBQ sauce gives the most classic flavor. Vinegar sauces can work too, just balance with a bit of brown sugar (about ¼ cup). Store-bought or homemade is fine.

Can you use another cut of meat for this recipe?

This recipe works with a lot of different cuts of beef. The key is to find something that has a good fat content that will benefit from the low and slow style of cooking. Brisket is a great option, especially if you are serving a larger crowd, but chuck roast, shoulder roast, and even beef short ribs are all great options.

You can also use this recipe as a guideline for smoking pork shouder, lamb shoulder, or other large cuts. It lends itself well to many different proteins.

Testing This Smoked Pulled Beef Recipe

Our original pulled beef recipe used a flat iron steak and a homemade coffee-based rub. It was a great showcase for rich, beefy flavor, but the cut could be tricky to source.

After more testing, we found that chuck roast delivers more consistent results for pulled beef. It’s more forgiving, better marbled, and breaks down beautifully during a low and slow cook.

We also simplified the seasoning to kosher salt and coarse black pepper during the smoke stage. Then we layered in flavor during the wrap with butter, barbecue sauce, and a sweet BBQ rub. This two-phase seasoning approach lets you build up bark without burning sugar, then finish with that classic saucy, smoky sweetness.

How to make Smoked Pulled Beef from Chuck Roast

1. Trim and season the chuck roast

Depending on where you buy your roast, prep should be minimal. Typically a beef chuck roast or shoulder roast come trimmed and essentially ready to cook. If you notice any small pieces hanging off or any uneven places you can do some light trimming with a boning knife, but you should not need to do much.

Short on time? You can also chop the chuck roast into chunks around 3”-4” wide. This can make the final roast a bit saltier because of the amount of seasoning you will use, so be sure to pull the punch a bit on the salt when seasoning if you opt for this prep method.

I like to keep the seasoning pretty simple for the first part of the cook. Just a bit of kosher salt and coarse ground black pepper so I can build up a bark for the first few hours.

You will add sauce, butter, and a sweeter seasoning during the wrap, so don’t worry – there will be plenty of flavor!

2. Smoking the chuck roast

The first step in the cooking process is just to get some smoke on your roast and start working on building some bark. Preheat the smoker (or pellet grill) to 250°F and place your chuck roast directly on the grates of the smoker.

For this recipe I used my Trager Ironwood XL pellet grill, but it can be made on just about any smoker or charcoal grill you have available. The key is to use a smoker that can hold a steady temperature of around 250°F for at least 5-6 hours.

When it comes to wood (or pellets, or charcoal), I recommend something bold but not overpowering. I’ve found that harsh woods like mesquite can overpower the flavor of the beef, so I try to opt for something a bit milder like oak or hickory. For this recipe I used the Bear Mountain Gourmet BBQ pellets, which is a nice blend of woods that add great flavor to the meat.

Depending on the size of your roast, the first part of the cook should take about 3 hours but the best way to check is to keep an eye on the internal temperature with an instant-read meat probe. I like to use my Thermoworks ThermaPen One for this because it’s quick (less than a second) and accurate.

Once your roast reaches around 165°F internal in the thickest part, the bark should be nice and firm and you’ll know it’s time to wrap it up.

3. Braising for pulled beef

Whenever I’m planning to shred meat, I braise it. This method is similar to the Texas Crutch used for brisket. It speeds up the cook and helps the meat stay moist and tender.

Braising not only reduces the overall cooking time, but it also adds flavor. I like to include a sweeter barbecue rub and some barbecue sauce for this step. This helps create that classic barbecue taste, similar to Texas-style chopped beef.

Once the meat is wrapped, it’s safe to add a rub with sugar since it won’t burn. A pork or rib rub works surprisingly well at this stage.

To set up the braise, transfer the chuck roast to a large aluminum pan. A roasting pan works too, but disposable pans make cleanup easier. Place the butter on top of the meat, then add the barbecue sauce and sprinkle with rub.

Wrap the pan tightly with foil to trap the steam and moisture. This turns the setup into a braising environment as the roast finishes cooking.

Place it back on the smoker and continue cooking for another 2 to 3 hours, depending on the size of the roast. The internal temperature should reach between 205 and 210°F.

To check if it’s done, slide a probe or toothpick into the meat. It should go in with almost no resistance, like softened butter.

Once it’s probe tender, remove the roast from the smoker and let it rest for 30 to 45 minutes. This lets the juices redistribute and makes it easier to shred.

4. Shredding Your Smoked Beef Roast

This beef will be so tender that you should be able to shred it easily with your hands. If it’s still a bit too hot to dig into, you can use gloves (I recommend nitrile gloves with cotton liners) to shred it apart. If you prefer a bit more civilized approach, feel free to shred it with forks or meat claws as well.

Once the meat is shredded, you can integrate some of the liquid from the braising pan to add moisture. Then, it’s ready to serve!

How to serve smoked chuck roast

My favorite way to serve this pulled chuck roast is on a sandwich with pickles and coleslaw, but it’s extremely versatile, which makes it a good option for Sunday meal prep to get you through the first few days of the week.

It tastes great on tortillas served up taco-style, but also stands alone. It’s also a good meat for stuffing Jalapeño poppers, baked potatoes, and other barbecue snacks!

Storing and Reheating Pulled Beef

Pulled chuck roast is ideal for leftovers. Let the meat cool completely, then store it in an airtight container in the fridge for up to 5 days, or vacuum seal and freeze for up to 3 months. For easy meal prep, portion it out before sealing and label each bag with the date and contents.

To reheat, place the vacuum-sealed bag in gently boiling water for 5 to 10 minutes, depending on the portion size. This method keeps the beef moist and flavorful without drying it out. If reheating in a pan, add a splash of beef stock or reserved juices, cover, and warm gently over low heat.

Smoked Chuck Roast Recipe

If you try this smoked chuck roast, let us know how it turns out in the comments. And if you love it, don’t forget to leave a five-star rating. It helps more people find the recipe!