Smoked Pulled Pork Recipe

The Best First Cook on a Pellet Grill

If you just bought a pellet grill and you are wondering what to cook first, this is it. Pulled pork is almost impossible to mess up. Pork butt has so much intramuscular fat and connective tissue that it stays moist even if you overcook it by 10 degrees. And the flavor? Deep, smoky, and rich without much effort.

I recommend this to every person I talk to who is new to pellet grills. I have made pulled pork on every grill I have tested, and it comes out great every single time. It is the most forgiving cook in BBQ.

Why Pork Butt, Not Pork Shoulder

Quick anatomy lesson. A "pork butt" is actually the upper part of the shoulder, not the rear end of the pig. The name is confusing but the cut is perfect for smoking. It has heavy marbling, a thick fat cap, and a bone running through the center that helps with even cooking.

You will sometimes see "pork shoulder" or "picnic roast" at the store. That is the lower part of the shoulder. It works for pulled pork too, but it has less fat and tends to dry out faster. Stick with pork butt (also labeled "Boston butt") for the best results.

Dealing with the Stall

Just like brisket, pork butt will stall around 150-170F. The stall on a pork butt can last 4 to 6 hours if you do not wrap. That is a long time to sit around watching a number not move.

Wrapping at 165F pushes through the stall in about an hour. I use butcher paper because it breathes, but foil is fine here. Pulled pork bark gets mixed into the meat anyway, so a softer bark from foil is not a problem the way it might be with brisket.

Pulling Technique

Use bear claws or two forks. Do not shred it too fine. You want chunks and shreds mixed together for texture. The bark pieces are the best part, so break those up and distribute them throughout.

Some people chop pulled pork. I am not one of those people. Pulling gives you better texture and you can see the smoke ring and bark in every serving. But if your crowd likes it chopped, go for it.

Serving Ideas

Classic sandwich: pulled pork on a brioche bun with coleslaw and pickles. But we also do pulled pork nachos, tacos, loaded baked potatoes, and even pizza. Ten pounds of pork butt feeds a lot of people and the leftovers are fantastic. It reheats well in a covered pan with a splash of apple cider vinegar to keep it moist.

Wood Pellet Pairing

Hickory is the traditional choice. Strong, smoky, and classic. Apple is lighter and sweeter, which works great if you are going for a more subtle smoke flavor. A blend of hickory and apple is my personal favorite for pulled pork. Our wood pellet guide breaks down all the flavor profiles.

Troubleshooting

Pork is dry

This is rare with pork butt, but it happens if you cook past 210F internal or if you bought a very lean cut. Make sure you are buying bone-in with a visible fat cap. The bone acts as a heat shield and the fat bastes the meat as it renders.

Bark is falling apart

Your rub might need more sugar to help it set, or you are spritzing too often. Spritz every hour, not every 30 minutes. Too much liquid washes the bark away before it firms up.

Instructions

1. Trim any loose flaps of meat and excess fat from the pork butt. You can leave the fat cap on, but score it in a crosshatch pattern so the rub can penetrate.
2. Coat the pork butt in a thin layer of yellow mustard. Mix all the dry rub ingredients and apply generously, packing it into every crevice.
3. Set your pellet grill to 225F with hickory or apple wood pellets. Place the pork butt fat side up on the grate. Insert a probe thermometer into the center of the thickest part.
4. Smoke undisturbed for the first 3 hours to let the bark develop. After that, spritz with apple cider vinegar every hour.
5. When the internal temperature hits 165F, wrap in butcher paper or foil. Return to the grill and continue cooking at 225F.
6. Cook until the internal temperature reaches 203-205F and a probe slides in with zero resistance. This usually takes another 4 to 6 hours after wrapping.
7. Remove from the grill and rest in the wrapping for at least 1 hour. A cooler with towels works great for holding temperature.
8. Unwrap, remove the bone (it should slide right out), and pull the pork apart with forks or bear claws. Mix the bark pieces throughout for flavor in every bite.