Pulled Pork Sandwich Recipe

Prepare rub and pork

Combine kosher salt, black pepper, paprika, brown sugar, garlic powder, onion powder, and cayenne pepper in a small bowl. Pat the pork shoulder dry with paper towels. Rub the vegetable oil over the entire roast, then rub the spice mixture evenly all over the pork, pressing it into crevices. Let rest at room temperature for 30 minutes or refrigerate up to overnight (if refrigerating, bring to room temperature 1 hour before cooking).

Preheat smoker or grill

Prepare your smoker to maintain a steady temperature of 225°F (107°C). If using a gas or charcoal grill, set up for indirect heat and place soaked wood chips on the coals or in a smoker box. Aim for consistent low-and-slow heat.

Smoke the pork

Place the pork shoulder fat side up on the smoker grate over indirect heat. Insert a probe thermometer into the thickest part of the meat, avoiding bone. Smoke until the internal temperature reaches about 160°F (71°C), about 4–6 hours depending on size and smoker consistency. Every hour, spritz the pork with a mixture of apple cider vinegar and apple juice (or water) to maintain moisture and encourage bark development.

Wrap (Texas crutch) and finish cooking

When the pork reaches 160–165°F and a good mahogany bark has formed (or at about 4–6 hours), wrap tightly in heavy-duty aluminum foil or butcher paper with a splash (2–4 tablespoons) of the apple cider vinegar/apple juice mixture. Return to the smoker and continue until the internal temperature reaches 195–205°F (90–96°C) and the meat is very tender, another 2–4 hours. The exact time varies; the meat is done when a probe slides in with little resistance.

Rest and pull

Remove the wrapped pork from the smoker and let rest, still wrapped, for 30–60 minutes. Carefully unwrap and transfer the pork to a large cutting board. Using two forks or meat claws, shred the pork into bite-sized pieces, removing excess fat and any bone. Reserve any juices in the foil and mix a few tablespoons into the shredded pork to keep it moist.

Combine ketchup, apple cider vinegar, brown sugar, molasses, Worcestershire sauce, mustard, smoked paprika, minced garlic, onion powder, salt, black pepper, and hot sauce (if using) in a medium saucepan. Whisk to combine.

Bring the sauce to a gentle simmer over medium-low heat. Reduce heat and simmer, stirring occasionally, for 10–15 minutes to meld flavors and thicken slightly. Taste and adjust seasoning (salt, sugar, or vinegar) to your preference. Remove from heat and let cool slightly. Reserve about 1 cup of sauce for serving and toss the rest with pulled pork if you prefer fully sauced meat (start with 1/2 cup per pound and add more to taste).

Toast buns: Heat a skillet or griddle over medium heat. Butter cut sides of buns and toast, buttered side down, until golden brown, about 1–2 minutes. Alternatively, place under a broiler for 1–2 minutes, watching carefully to avoid burning.

Assemble sandwiches: Place a generous portion (about 1/2 to 3/4 cup) of pulled pork on the bottom bun. Spoon Original BBQ Sauce over the pork (about 1–2 tablespoons for lightly sauced or more to taste). Top with prepared coleslaw if using, and add pickles if desired. Cover with the top bun.

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