Coffee and Chile Rubbed Smoked Pork Butt

Coffee and Chile Rubbed Smoked Pork Butt
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The pillars of great barbecue are built on old-school traditions rooted in simplicity.  Traditionalists would say that all you need to make a perfect smoked pork butt are some hot coals, a hunk of meat, and a little BBQ sauce.  For the new-age barbecue master, however, take advantage of modern smoking equipment designed to make your journey pork perfection even easier.  Char-Broil’s SmartChef technology lets you control your smoker’s cooking settings using any smart device, or try smoking a pork butt using your electric or gas grill.  Just place wood chips directly on hot grill grates and let the smoking begin.  It might not be traditional, but it can’t get any simpler than that.

How to Make Smoked a Pork Butt on the Grill:

  1. Select cut.  Choose a 3-5 pound pork butt with a light pink color and marbling throughout.  Be sure to select a cut with a nice layer of fat covering the top.
  2. Prepare the cut. Smear yellow mustard on the meat (you won’t taste the mustard once the meat is smoked) and add a smoked pork butt rub for flavor.  Wrap meat in plastic wrap and let refrigerate overnight.  Remove from fridge, unwrap, and place meat (fat cap up) in a disposable metal roasting pan.
  3. Preheat grill with indirect heat and add wood chips of a sweet flavor, like apple or hickory.   Read more about smoking wood flavors.
  4. Smoke pork.  Place pan with pork on grill and close lid.  Check wood chips every 30 minutes to see if they are still smoking.  If not, add another handful to smoker box or grill grate.
  5. Check internal temperature using a digital meat thermometer to know when the pork is done.  It will be finished cooking when it reaches 200°F.
Pork butt rubbed and ready for smoking on the grill.

Avoid Over-Smoking

Pork that is exposed to smoked for too long can sometimes take on a bitter flavor.  To prevent this, we suggest not adding anymore wood chips once the meat has reached 160°F.  Let the pork finish cooking by the heat of the grill or roast in a 200°F oven.


  • Know that pork temperature has a tendency to plateau around 165°F. Don’t increase the heat intensity of the grill. Be patient and wait for the internal temperature to rise until 200°F so pork will be fully cooked.
  • Look for the pork to slightly slump in on itself.  This is a sign that the collagen of the meat has dissolved and the pork is tender and ready to be taken off the heat of grill, oven, or smoker.
  • Cook times will vary.  A 3 pound pork will take about 3 hours. For more info about cooking times, check out our guide for smoked pork temperature and cook times.

Pork Butt

 Smoker Temperature:  240°F
 Smoking Time:  14 hrs
 Finished Temperature:  200°F
Smoked BBQ Boston Butt in an Electric Smoker 


Coffee and Chile Rubbed Smoked Pork Butt


Prep Time: 15 minutes

Cook Time: 4 hours

Total Time: 4 hours, 15 minutes

Yield: 1 pork butt

Serving Size: --

Calories per serving: --

Fat per serving: --

Create a beautifully smoky and juicy pork butt on your gas grill.


  • 1/4 cup ancho chile powder
  • 1/4 cup finely ground coffee
  • 2 tablespoons dark brown sugar
  • 1 tablespoon paprika
  • 1 tablespoon dry mustard
  • 1 tablespoon salt
  • 1 tablespoon pepper
  • 1 tablespoon coriander
  • 1 tablespoon oregano
  • 2 teaspoons ginger
  • 1 3-5 pound pork butt
  • Yellow mustard
  • Hickory chips


  1. Combine all the dry ingredients.
  2. Rub the pork butt with yellow mustard and apply the rub. Wrap in plastic wrap and refrigerate for several hours or overnight.
  3. Preheat the grill using the indirect method with two burners on high and two burners unlit.
  4. Place a handful of hickory chips on the lit side. Or, if using a foil pouch, place a handful of chips in a square of heavy duty tin foil. Fold all sides and poke a small hole in the top.
  5. When the chips start to smoke, place the butt in a aluminum half pan on the unlit side of the grill, turn the lit side to low and close the lid.
  6. Replace the wood chips every 20-30 minutes until the internal temperature of the butt reaches 140 degrees.
  7. Either continue cooking on the grill or place in a 250-degree oven until the internal temperature of the butt reaches 200 degrees.
  8. Let the butt rest for 30 minutes before pulling.

Don’t stop with just smoking pork butt!  Visit the Char-Broil community page to find other great smoked pork recipes like Apple Wood Smoked Pork Loin or BBQ Smoked Shredded Pork Belly.  

apple wood chips for smoking


Apple Wood Chips - 2 lb. Bag

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