Pulled Pork Sandwich Recipe

Trim and Prep Pork

Trim excess large pockets of fat from the pork shoulder, leaving a thin fat cap for flavor. Pat the meat dry with paper towels.

Make Dry Rub

In a bowl, combine kosher salt, coarse black pepper, paprika, brown sugar, garlic powder, onion powder, ground cumin, and chili powder. Mix until even.

Apply Binder and Rub

Lightly coat the pork shoulder all over with vegetable oil or a thin layer of mustard (this helps the rub adhere). Generously massage the dry rub onto the entire surface of the pork, covering all sides. Let rest at room temperature 30 minutes or refrigerate up to overnight (bring to room temp before smoking).

Prepare Smoker

Preheat your smoker to 225°F (107°C). If using a charcoal/offset smoker, set for indirect heat. Add soaked or dry wood chips/chunks (hickory, apple, or oak) to produce steady smoke.

Place Pork on Smoker

Place the pork shoulder fat-side up on the smoker grate. Insert a probe thermometer into the thickest part of the meat, avoiding bone. Close the lid and smoke.

Maintain Temperature and Spritz

Maintain smoker temperature at 225°F ±10°F. Every 60–90 minutes, spritz the pork with a mixture of apple cider vinegar and apple juice (or water) using a spray bottle to keep the surface moist and encourage bark formation. Continue smoking until internal temperature reaches about 195–203°F (90–95°C) and the meat is very tender and a probe slides in like butter — plan on approximately 1.5 to 2 hours per pound depending on smoker and consistency.

Wrap (optional stall-busting)

If the pork stalls around 150–165°F and you want to speed up the process while retaining moisture, tightly wrap the pork in butcher paper or aluminum foil (Texas crutch) with a splash of apple juice before returning to the smoker. Continue cooking until 195–203°F.

Rest and Shred

When target temperature is reached and the pork is tender, remove from the smoker and let rest, wrapped, for 30–60 minutes. Transfer to a cutting board and use two forks or meat claws to pull the pork into shreds. Discard excess fat and bone. If desired, mix in 1/2 to 1 cup of your chosen barbecue sauce to moisten and flavor the meat (reserve extra sauce for serving). Taste and adjust seasoning with salt, pepper, or a splash of apple cider vinegar.

Prepare Rolls

Split the Kaiser rolls and lightly butter the cut sides. Toast on a griddle, skillet, or under a broiler until golden and slightly crisp, about 1–2 minutes per side.

Assemble Sandwiches

Place a generous portion (about 1/2 cup to 3/4 cup) of pulled pork on the bottom half of each toasted roll. Spoon additional barbecue sauce over the pork if desired. Top the pork with about 1/4 cup of coleslaw and a few pickle slices if using. Cap with the top roll.

Serve

Serve immediately while hot with extra barbecue sauce on the side. Leftover pulled pork can be refrigerated up to 4 days or frozen for up to 3 months.