Smoked Chicago Italian Beef Sandwich on a Pellet Grill?

Smoked Chicago Italian Beef Sandwich on a Pellet Grill?

Craving a classic Chicago Italian beef sandwich with a smoky twist? This comprehensive recipe will guide you to create a savory, melt-in-your-mouth delight right at home.

You Will Need

  • 3-4 lb beef roast (top round is a good choice)
  • 2 Cans Beef Consomme
  • ½ bottle Kosmos Q Brisket Mop
  • 1 Yellow Onion
  • 1 Red Bell Pepper
  • 2 Tbsp olive oil
  • 3 Tbsp Kosmos Q Lab Italian seasoning blend
  • 2 tsp Kosmos Q SPG rub
  • 2 tsp Kosmos Q Cow Cover rub
  • 1 tsp red pepper flakes (optional for heat)
  • Italian-style hoagie rolls (Sams)
  • Giardiniera (Italian pickled vegetables), for serving
  • Roasted red peppers for serving
  • Provolone cheese, sliced (optional)

The Prep

Start by preparing your beef roast. Rub it generously with olive oil, ensuring an even coating on all sides. Next, apply the Kosmos Q Lab Italian seasoning blend, as well as SPG and Cow Cover seasoning over the entire surface of the beef. Don’t forget to season the edges as well - every bite should be packed with flavor!.

Once seasoned, let the beef sit at room temperature. In the meantime, slice your yellow onion and red bell pepper, setting them aside for later use. Preheat your pellet grill to 250°F (121°C), with wood pellets like hickory or oak to complement the beef's flavor. 

Finally, place a pan beneath the grill grates to collect the drippings. These will be gold for the Au Jus later on!

The Cook

Once everything is ready, place the seasoned beef directly on the grill grates, allowing it to smoke low and slow. You’re aiming for an internal temperature of about 165°F (74°C) to develop a nice bark, which should take around 2-3 hours depending on the size of your roast. 

When the beef has reached the desired internal temperature, wrap it in foil with the sliced onions, red peppers, 1 can of beef consume, and ½ bottle of brisket mop. Seal the foil carefully to avoid any tears, and return it to the grill.

Continue cooking until the internal temperature hits 204°F (95°C), which ensures the beef is tender enough to shred. Let the beef rest in the foil for at least 20 minutes to allow the juices to redistribute. 

The Payoff

While the beef rests, prepare the au jus by combining beef broth, soy sauce, Worcestershire sauce, onion, and garlic in a saucepan with the collected drippings from the grill. Let it simmer and reduce slightly for a concentrated, delicious dip.

Once ready, shred (or slice) the beef against the grain, and allow it to soak in the Au Jus. This step is key to achieving the signature moistness and flavor of a Chicago Italian Beef Sandwich.

Let's assemble your sandwiches! Lightly toast the hoagie rolls on the grill. Layer the shredded beef or slices onto the rolls, dipping each piece briefly in the au jus for that extra moistness. Top with provolone cheese (if used), giardiniera, and roasted red peppers. Serve with extra au jus on the side.

Enjoy your smoky, savory masterpiece!


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