Name: Big Island Kona Mix Plates BBQ Kalua Pork Sandwich Recipe
Cook time: 10 h
Total time: 10 h
Yield: 8 servings
Ingredients: 4 lbs pork shoulder (Boston butt), boneless; 2 tbs kosher salt; 2 tbs light brown sugar, packed; 2 tsp liquid smoke (hickory or mesquite); 1 tsp garlic powder; 1 tsp onion powder; 1 tsp black pepper, freshly ground; 1 cup water; 1 tbs apple cider vinegar; 1 cup ketchup; 2 tbs apple cider vinegar; 2 tbs brown sugar; 1 tbs Worcestershire sauce; 1 tsp yellow mustard; 1 tsp smoked paprika; 2 cloves garlic, minced; 1 tsp hot sauce (optional); 1 tsp salt; 0.5 tsp black pepper; 8 pieces hamburger buns (or brioche buns); 2 tbs butter, softened (for toasting buns); 4 cups coleslaw, creamy (store-bought or homemade); 0.5 cup pickles (sliced, optional); 0.25 cup fresh cilantro or chopped green onion (optional garnish)

Method

Kalua-style smoked pork

Trim and season

Pat the pork shoulder dry with paper towels. Trim excess large fat caps but leave some for flavor. In a small bowl combine kosher salt, brown sugar, garlic powder, onion powder and black pepper. Rub the mixture all over the pork. Drizzle the liquid smoke evenly over the exterior and rub it in. Place the pork in the insert of a slow cooker or in a foil-lined roasting pan if using the oven.

Add braising liquid

Pour 1 cup water and 1 tablespoon apple cider vinegar into the bottom of the slow cooker or pan — you want some steam for moisture but not to cover the meat.

Slow-cook

Slow-cooker method: Cover and cook on LOW for 8–10 hours or HIGH for 4–5 hours, until the pork easily shreds with two forks and reaches ~195–205°F (90–96°C) internal temperature. Oven method: Preheat to 275°F (135°C). Cover the pan tightly with foil and roast for 5–7 hours until very tender and shreddable.

Rest and shred

Remove pork to a large cutting board or bowl and let rest 15 minutes. Reserve ~1/2 cup of cooking juices. Using two forks or meat claws, shred the pork into bite-sized pieces, discarding any excessive large chunks of fat. Stir in a few tablespoons of the reserved juices to keep the meat moist.

BBQ sauce (for finishing)

Make the sauce while the pork rests: In a small saucepan combine ketchup, apple cider vinegar, brown sugar, Worcestershire sauce, mustard, smoked paprika, minced garlic, hot sauce (if using), salt and pepper. Warm over medium-low heat, stirring until sugar dissolves and sauce is slightly thickened, about 6–8 minutes. Taste and adjust seasoning. Remove from heat.

Mix with shredded pork: Transfer about 2 cups (or desired amount) of the shredded pork to a large skillet over medium heat. Pour 3/4 to 1 cup of the prepared BBQ sauce over the pork and toss to coat and warm through, 3–5 minutes. Add more sauce to taste and stir in up to 2 tablespoons of reserved cooking juices if the pork seems dry. Reserve remaining sauce for serving.

Sandwich assembly

Toast buns: Heat a large skillet or griddle over medium heat. Butter the cut sides of the buns. Toast buttered sides in the skillet until golden, about 1–2 minutes.

Build sandwiches: Pile 1/2 to 3/4 cup of sauced shredded pork on the bottom half of each bun. Top with a generous scoop (about 1/2 cup) of creamy coleslaw, a few pickle slices if using, and a sprinkle of chopped cilantro or green onion. Place top bun and press lightly.

Serve: Serve immediately with extra BBQ sauce on the side. Leftover pork keeps well refrigerated up to 4 days or frozen for 3 months.

Bbq Kalua Pork Sandwich Recipe