Coffee and Chile Rubbed Smoked Pork Butt

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.

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.
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