This smoked chuck roast is a simple, reliable way to get deep beefy flavor without committing to an all-day brisket cook. It’s rich, forgiving, and perfect for piling onto sandwiches once it’s pulled!
Don’t confuse a chuck roast with brisket: they’re often compared, but they’re not the same cut. Brisket comes from the lower chest and is long, flat, and leaner with a distinct fat cap, while chuck comes from the shoulder. Chuck has more internal marbling and connective tissue, which makes it incredibly flavorful and much more forgiving to cook. It also finishes faster, making it a great option when you want that smoked beef payoff without the marathon.
For this cook, we wanted to check how close to a brisket we could get. To get started, use W Sauce as a binder, coating the chuck roast lightly but evenly so the seasoning sticks. Season generously with Double Pepper Cow Cover, followed by Texas Beef rub to round things out with a classic beef-forward profile. Once seasoned, let the meat sit at room temperature for about 1 hour. This gives the rub time to sweat into the surface while you set up the cooker, helping build a better bark once it hits the smoke.
Preheat your smoker to 275°F (135°C), using hickory wood and lump charcoal for a strong but balanced smoke. When the smoker is up to temp, place the chuck roast over indirect heat. As it cooks, the surface will darken to a rich, mahogany color.
While the chuck roast is cooking, prepare the au jus that will be used when wrapping. Mix 1/2 bottle of brisket mop with one 10-ounce can of beef consommé to create a rich au jus. Stir well and let it come to room temperature; adding cold liquid to hot meat can stall the cook and tighten the fibers.
Once the roast reaches 160–165°F (71–74°C), pull it from the smoker. Lay out a double layer of aluminum foil, place the chuck roast in the center, and form a tight foil pocket. Set it into a foil pan to avoid spilling, pour the au jus inside the foil pocket, and seal everything up before returning it to the smoker.
After about an hour wrapped, start monitoring the internal temperature closely with a BBQ thermometer. You’re aiming for tenderness, not just a number. Around 205°F (96°C) is usually the sweet spot, but depending on the cut, you may need to push it as far as 215°F (102°C). When it’s ready, the probe should slide in and out with almost no resistance. Once there, bring the roast inside, carefully open the foil, and let it vent steam for about 30 minutes.
After venting, pour off and reserve the au jus, then rewrap the chuck roast and let it rest for another 15–20 minutes. While it rests, it’s the perfect time to knock out some sides! Fries work especially well, seasoned with something bold like Garlic Parm wing dust.
When the meat is done resting, pull it apart for sandwiches, mixing some of the reserved au jus back in to keep everything juicy. Build your sandwich with your favorite toppings and sauces (we went with pickles, onions, Garlic Parm fries on the side, and OP X-1 sauce for a finishing kick). How does smoked chuck roast to smoked brisket? We'll let you find out.
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