Smoked Pulled Pork Bbq Recipe

Trim and season

Trim excess hard fat from the pork shoulder, leaving a thin fat cap for flavor. Pat the pork dry with paper towels and spread the yellow mustard over the exterior to act as a binder for the rub.

Make the dry rub

In a small bowl combine kosher salt, black pepper, paprika, brown sugar, garlic powder, onion powder and cayenne. Stir until evenly blended.

Apply rub

Rub the spice mixture all over the mustard-coated pork, pressing to adhere. Cover and refrigerate for at least 2 hours or up to overnight to let flavors penetrate.

Prepare smoker

Preheat your smoker to 225°F (107°C). If using charcoal/gas grill set up for indirect cooking. Add hickory or oak chunks/chips according to manufacturer instructions to generate a steady mild smoke. Place a water pan in the smoker to help maintain humidity and add the apple juice/cider to the water pan for additional aroma.

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°F (71°C). This takes roughly 4–6 hours depending on size and smoker consistency. Every 1–2 hours spritz the pork with apple juice to keep the surface moist and help form a good bark.

Wrap in foil (Texas crutch)

When the pork hits 160°F (71°C) and a nice bark has formed, remove it and tightly wrap in heavy-duty aluminum foil or butcher paper. Before sealing, add 1/4 cup apple juice into the packet to keep the meat moist. Return to the smoker.

Finish to tenderness

Continue smoking until the internal temperature reaches 203°F (95°C) or until a probe slides in with little resistance, about another 2–4 hours. Total cook time is usually 8–12 hours for a 4-lb shoulder. Remove from smoker and let rest in the foil for at least 30–60 minutes to redistribute juices.

Pull the pork

Carefully unwrap the rested pork and transfer to a large cutting board or shallow pan. Use two forks or meat claws to shred the pork into bite-sized strands, discarding any excessive gristle or bone. Skim and reserve 1/2 cup of the cooking juices from the foil and mix into the shredded pork to moisten it as desired.

Heat the oil in a medium saucepan over medium heat. Add the finely chopped onion and cook, stirring occasionally, until softened and translucent, about 4–5 minutes.

Add the minced garlic and cook for 30–45 seconds until fragrant, careful not to burn.

Stir in the ketchup, apple cider vinegar, molasses, brown sugar, Worcestershire sauce, yellow mustard, smoked paprika, chopped chipotle, hot sauce (if using), salt and black pepper. Bring to a gentle simmer.

Reduce heat to low and simmer uncovered for 10–15 minutes, stirring occasionally, until slightly thickened. If the sauce is too thick, whisk in up to 1/4 cup water to reach desired consistency.

Taste and adjust seasoning — add more sugar for sweetness, vinegar for tang, or chipotle/hot sauce for heat. Remove from heat and let cool slightly. For a very smooth sauce, blend with an immersion blender or regular blender until uniform.

Reserve about 1/2 cup of the sauce to toss with the shredded pork and keep the remainder warm for serving.

Warm the reserved Lonestar BBQ sauce in a small saucepan over low heat.

Place the shredded pork in a large bowl and pour about 1/2 cup (or to taste) of the warm Lonestar sauce over the pork. Gently toss to coat evenly. Add a splash of reserved cooking juices if the pork seems dry. Taste and adjust—add more sauce, salt or pepper if needed.

Butter the buns lightly and toast them on a hot skillet or grill for 1–2 minutes until golden.

Build sandwiches by placing a generous scoop of sauced pulled pork on the bottom bun, topping with 1–2 tablespoons of sliced bread-and-butter pickles, a sprinkle of chopped cilantro or parsley (optional), and a drizzle of extra Lonestar sauce. Cap with the top bun.

Serve immediately with extra sauce and pickles on the side.