Pulled Pork Sandwich Recipe

Trim and prepare

Trim excess fat from the pork shoulder, leaving an even 1/4–1/2-inch fat cap. Pat the meat dry with paper towels. If desired, use a syringe to inject 1/2 cup apple juice evenly into the thickest parts of the roast to help retain moisture.

Preheat smoker

Preheat your smoker to a steady 225°F (107°C). Add hickory wood chunks to the coals or wood box so you get a steady hickory smoke flavor during the cook.

Apply rub

Generously apply the prepared dry rub all over the pork shoulder, pressing it into the meat so it adheres. Let the rubbed pork rest at room temperature 20–30 minutes while the smoker finishes coming to temperature (or refrigerate overnight for deeper flavor; if refrigerated, bring to room temp 30–60 minutes before smoking).

Smoke the pork

Place the pork shoulder fat-side up on the smoker grate. Smoke at 225°F (107°C) until the internal temperature reaches about 160–165°F (71–74°C), roughly 3–4 hours depending on size and smoker. Begin mopping (see Mop & Sauce section) every hour once smoke is established, but avoid opening the smoker unnecessarily.

Continue to stall and finish

After the stall (around 160–170°F), continue smoking until the pork's internal temperature reaches 195–205°F (90–96°C). This final temp range yields meat that will pull easily and be moist. Expect total smoke time ~5–7 hours for a 5 lb shoulder; watch internal temperature rather than time.

Rest

Remove the pork from the smoker when it reaches target temperature. Tent loosely with foil and let rest in a cooler or insulated container for 45–60 minutes. Resting lets juices redistribute and makes pulling easier.

Pull

Unwrap and use two forks or meat claws to shred the pork into bite-sized pieces, removing any large pockets of fat or bone. Transfer pulled pork to a large tray or pan and reserve the juices. Keep warm until assembling sandwiches.

Combine the dry rub ingredients (brown sugar, paprika, kosher salt, black pepper, garlic powder, onion powder, cumin, cayenne) in a bowl and mix until uniform. This makes enough rub for the 5 lb shoulder. Use all of the rub when applying to the pork as directed in the "Apply rub" step above; press the rub firmly into the surface so it forms a bark while smoking.

Make the mop liquid

Whisk together 1 cup apple cider vinegar and 1/2 cup apple juice. Place in a spray bottle or ladle. Beginning after the first 1–2 hours of smoke, gently mop or spritz the pork every 45–60 minutes to keep the surface moist and add tang. Do not over-saturate; a light coating is enough.

Make the finishing BBQ sauce

While the pork rests, make the barbecue sauce: combine 1 cup ketchup, 2 tbs brown sugar, 1 tbs Worcestershire, 1 tbs Dijon mustard, 1 tsp hot sauce, 0.5 tsp salt, 0.5 tsp black pepper and 2 tbs butter in a small saucepan. Simmer gently 8–12 minutes, stirring, until slightly thickened and glossy. Adjust salt or sweetness to taste. Keep warm.

Mix with pulled pork (optional)

If you prefer a saucy pulled pork, fold 1–1.5 cups of the finished BBQ sauce into the shredded pork until well coated. Reserve extra sauce for serving on the side.

Prepare slaw

In a medium bowl combine 3 cups shredded cabbage and 1 cup shredded carrot. In a separate small bowl whisk together 3/4 cup mayonnaise, 2 tbs apple cider vinegar, 1 tbs sugar, 1/2 tsp celery seed, 1/2 tsp salt, 1/4 tsp black pepper and 1 tbs lemon juice (if using). Pour dressing over cabbage mixture and toss to combine. Chill at least 20–30 minutes to meld flavors. Serve cold on top of pulled pork or on the side.

Prep garnishes

Wash and pat lettuce leaves dry. Have dill pickle slices ready for each sandwich.

Toast buns

Butter the cut sides of 8 hamburger buns with the 2 tbs unsalted butter. Toast cut-side down on a hot griddle, skillet, or under a broiler until golden and lightly crisp, about 1–2 minutes. Keep warm.

Assemble sandwiches

Pile 1 to 1 1/4 cups of pulled pork (with or without mixed-in sauce) onto the bottom half of each toasted bun. Top with a generous scoop of coleslaw (if using) or a lettuce leaf. Add 1 dill pickle slice (or several) and finish with the top bun. Serve extra BBQ sauce on the side and pass remaining coleslaw.

Serve

Serve the sandwiches hot alongside pickles, extra sauce, and any sides you prefer (fries, baked beans, potato salad). Leftover pulled pork keeps well in the fridge for 3–4 days or freezes for longer storage.