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Simple Smoked Pulled Beef Sandwiches (Chuck Roast) Recipe

If you're trying to feed a crowd and they're sick of pulled pork, chopped beef is the best option.
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By Dylan Clay
November 12, 2024
pulled beef sandwich recipe

What Cut of Beef to Use?

Chuck roast is small and cheaper than most cuts – look for around 2-3 lbs.

Other cuts that work:

  • Beef cheeks
  • Brisket

With brisket, I like to combine 50/50 of point and flat meat.

Dry Rub for Pulled Beef

This combines My seasoned salt with 16 mesh black pepper:

  • 1/4 cup Diamond Crystal Kosher Salt
  • 2 tbsp 16 Mesh black pepper
  • 1.5 tbsp Caster Sugar
  • 2 tbsp turmeric
  • 2 tbsp paprika
  • 1 tbsp granulated garlic
  • 1/2 tbsp granulated onion
  • 1/2 tbsp ground mustard
  • 1 tsp ground celery seed

Mix well and then apply the above rub liberally to all sides of the chuck roast.

Get Your Smoker to 250-275F and Put the Chuck Roast On

Smoke with your favorite hardwood – I used post oak.

Add new wood every 45-60 minutes.

chuck roast on smoker

Smoke Until the Bark is Dark, then Wrap

This “dark bark” will happen at around 170F internal.

For me, this was after 5 hours and 15 minutes of smoking.

chuck roast after 5 hours of smoking

Wrap the meat up up with 2 layers of aluminum foil and return to the smoker or your kitchen oven set to 275F.

Smoke the Meat Until Probe Tender

This will happen at around 205F+ internal.

We’re not super concerned with overcooking the meat here since it’s all going to be chopped and pulled together regardless.

You should be able to take your probe and it will go through the chuck roast with ZERO effort.

Rest for 30-45 Minutes then Chop and Pull the Beef

When you pull the meat, remove any bits of connective tissue or any pieces of unrendered fat.

Essentially anything you think wouldn’t be appetizing to eat.

pulled beef chuck roast

When you pull you can:

  • Pour some of the juices that have inevitably accumulated in the foil wrap onto the meat.
  • You can dust the meat with more of your rub.
  • Add your favorite BBQ sauce.

You get the gist.

I made these into sandwiches.

I like to top with BBQ sauce and homemade pickled red onions and dill pickles.

Simple Smoked Pulled Beef Sandwiches

For when you're sick of pulled pork every BBQ
Prep Time5 minutes
Active Time7 hours 45 minutes
Rest Time45 minutes
Total Time8 hours 35 minutes

Ingredients

  • 2.6 lb Chuck Roast

Rub for Pulled Beef

  • 1/4 cup Diamond Crystal Kosher Salt
  • 2 tbsp 16 Mesh black pepper
  • 1.5 tbsp Caster Sugar
  • 2 tbsp turmeric
  • 2 tbsp paprika
  • 1 tbsp granulated garlic
  • 1/2 tbsp granulated onion
  • 1/2 tbsp ground mustard
  • 1 tsp ground celery seed

Instructions

  • Take chuck roast out of package and pat dry.
  • In a bowl combine dry rub ingredients in specified quantities.
    1/4 cup Diamond Crystal Kosher Salt, 2 tbsp 16 Mesh black pepper, 1.5 tbsp Caster Sugar, 2 tbsp turmeric, 2 tbsp paprika, 1 tbsp granulated garlic, 1/2 tbsp granulated onion, 1/2 tbsp ground mustard, 1 tsp ground celery seed
  • Season chuck roast liberally on all sides with rub.

Get Smoker to 250-275F

  • Once at temperature, put chuck roast on.
  • Every 45-60 minutes add a new chunk of your favorite hardwood.
    I used post oak.
  • Once the internal temperature reaches 170F internal and the bark is dark, take off the smoker to wrap.
    For me, this took 5 hours and 15 minutes.

Wrap Chuck Roast in 2 Layers of Aluminum Foil

  • Take the chuck roast and put into 2 layers of aluminum foil. Wrapping tight so no steam can escape.
  • Leave wrapped for 1 hour and then check tenderness.

Take off the Smoker Once Tender

  • Internal temperature should be around 205F+ and your probe should slide in and out of the meat with NO resistance.
  • Leave wrapped and put into your kitchen oven for 45 minutes.

Shred the Meat

  • Pull the meat and shred it to your desired consistency.
    Remove any pieces of unrendered fat and any connective tissue.
    Essentially anything that you wouldn't want to eat, remove.
    I used this meat for sandwiches – I topped with homemade BBQ sauce and pickled red onions (linked below).

Notes

I topped with homemade: 

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