Smoked Chili | Recipe for Chuck Roast Chili Smoked on Grill

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A big bowl of hearty chili is the perfect way to warm up on a cold day and I want to share with you my recipe for making Smoked Chili on the grill. This recipe starts with a chuck roast that I smoke prior to making the chili. If you happen to have some left over brisket it does just as well in this dish.

Fire up your smoker and bring the temp up to 250⁰. Season the outside of the chuck roast or brisket with your favorite Rub. I use a mixture of my AP and other spices; here’s the recipe:

- 1 Tablespoon Killer Hogs AP Rub
- 1 Tablespoon Chili Powder
- 1 Tablespoon Onion Powder
- 1 Tablespoon Cumin
- 2 teaspoon Paprika
- 1 teaspoon Oregano
- 1 teaspoon Cayenne Pepper
- 1 teaspoon Chipotle Pepper

Combine these ingredients and liberally dust over all sides of the chuck roast. Place the roast on the smoker and let it cook for about 4 hours.

The internal temp should be around 180 degrees. I want it a little firm (not falling apart) for this recipe because it will be cubed and simmered for several hours until it’s melt in your mouth tender! Place the cubed roast in refrigerator overnight until ready to use.

For this chili I’m firing up my Big Green Egg; you can cook it on any type grill set up for indirect cooking just run temp between 275-300 degrees.

I don’t add wood for this cook because the chuck roast has plenty of smoky flavor to add to the chili and I char grill the vegetables for even more grill taste.

Once the coals are hot, place the cooking grate in place, and let it heat up for a few minutes. The plate setter goes on later because I’m grilling the Poblano, Bell Pepper and Onion first. Place each directly on the cooking grate over the hot coals for a few minutes on each side to char.

Grilling the veggies makes them extra sweet. Remove the seeds from the peppers and chop everything into small pieces. Then use a pair of high heat gloves and place the plate setter under the cooking grate to create indirect cooking on the Egg.

The last bit of prep for the chili is my secret ingredient, 1 pound of spicy hot breakfast sausage. Just brown it in a skillet and drain off the excess oil. This kicks up the spice level a bit and gives the chili a rich flavor.

Now we’re ready to combine the ingredients for the chili.

I use a 5 quart black iron pot and add the chopped vegetables and a 24oz can of diced tomatoes. Add 3-4 cloves of minced garlic, 3 Chipotle Peppers in Adobo Sauce, the chuck roast, and the spicy sausage. Dump in the chili seasonings and stir to combine.

Chili Seasoning:
- 1/3 cup Sugar
- 2 Tablespoons Killer Hogs AP Rub
- 2 Tablespoons Chili Powder
- 1 Tablespoon Ground Cumin
- 1 Tablespoon Onion Powder
- 2 teaspoons Paprika
- 1 teaspoon Ground Chipotle Pepper
- 1 teaspoon Ground Ancho Chili Pepper
- 1 teaspoon Oregano
- ¼ teaspoon Cayenne Pepper (more if you like it spicy)

Pour in ¼ cup of Worcestershire Sauce and 2 Tablespoons of your favorite Hot Sauce (you know I’m using my Killer Hogs Hot Sauce!), 2 Tablespoons Tomato Paste, and 1 quart of Beef Broth. Stir the chili to combine and place on the Big Green Egg uncovered.

Simmer the chili for 2 ½ hours and you’ll want to stir it a couple of times throughout the cook. At this point add 1 can of Chili Beans to the pot. Adding the beans at this point keeps them from getting a mushy texture. I know there’s a big debate about beans in chili but I personally like them in mine. If you don’t like beans just skip this step.

Keep simmering the chili for another hour and it’s ready to serve.
Carefully remove the pot from the grill (wear some high heat gloves) and serve with your favorite chili toppings.

I like Shredded Cheese, Sour Cream, Fresh Cilantro and Lime wedges but you can serve it with anything you like. This chili is rich and hearty with a smoky flavor, the tender bites of chuck roast melt in your mouth, and the spices have just the right heat. Gives this chili a try the next time you’re craving a hearty meal!

For Killer Hogs BBQ Sauce, Rub and Competition BBQ equipment, visit: https://h2qshop.com/

Smoked Chili Recipe