Pulled Pork Sandwich Recipe

Prepare the pork

Trim excess silver skin from the pork shoulder, leaving a thin fat layer for flavor. Pat dry with paper towels.

Combine kosher salt, black pepper, brown sugar, smoked paprika, garlic powder and onion powder in a small bowl. Rub the pork all over with yellow mustard, then apply the dry rub evenly, pressing to adhere.

Let the rubbed pork rest in the refrigerator for at least 2 hours or overnight for best flavor (optional).

Prepare your smoker for indirect cooking at a steady 225°F (107°C). Add soaked wood chips or chunks (hickory or apple) to the smoker to produce smoke.

Place the pork shoulder on the smoker fat-side up. Insert a probe thermometer into the thickest part, avoiding bone. Smoke until internal temperature reaches about 195–205°F (90–96°C), roughly 8–10 hours for a 4 lb shoulder. Add apple juice or water to the smoker water pan every few hours to maintain moisture and add soaked wood as needed.

When the pork reaches 160–170°F (71–77°C) and has a firm bark, spritz with apple cider vinegar every 45–60 minutes if desired to help develop bark and moisture.

Once the pork reaches 195–205°F, remove it from the smoker and wrap tightly in foil or butcher paper. Let rest for 30–45 minutes to allow juices to redistribute.

Unwrap the pork and use two forks or meat claws to pull the meat into shreds. Discard any large pieces of gristle or excess fat. Mix in 1/2 to 1 cup of the Carolina fire BBQ sauce (reserve the rest for serving) and 2–3 tablespoons of the pan juices or extra apple cider vinegar to moisten. Taste and adjust seasoning with salt and pepper to taste.

Combine apple cider vinegar, ketchup and light brown sugar in a medium saucepan over medium heat. Whisk until sugar dissolves.

Add hot sauce, Worcestershire sauce, yellow mustard, smoked paprika, red pepper flakes, salt and black pepper. Stir to combine.

Bring the mixture to a low simmer, then reduce heat to low and cook uncovered for 8–12 minutes, stirring occasionally, until slightly thickened and bright in flavor. Taste and adjust heat or sweetness as desired.

Remove from heat and let cool to room temperature. Sauce will thicken slightly as it cools. Reserve 1/2 to 1 cup for mixing into pulled pork and the remainder for serving.

Prepare fries according to package directions or your preferred method. For fresh fries: heat vegetable oil in a deep fryer or heavy pot to 350°F (175°C). Fry fries in batches until golden and crisp, 3–5 minutes per batch. Drain on paper towels and immediately season with 1 tsp salt. For oven fries: toss with 1–2 tbs oil and roast at 425°F (220°C) for 20–30 minutes, turning once, until crisp.

Split buns and lightly butter the cut sides with softened butter. Toast the buns on a hot griddle, skillet, or under a broiler until golden-brown, about 1–2 minutes per side. Keep toasted buns warm.

To assemble each sandwich: pile approximately 1/2 cup (about 4 oz) of pulled pork onto the bottom bun. Spoon 1–2 tablespoons of extra Carolina fire BBQ sauce over the pork (or to taste). Add a generous pinch of dill pickle chips across the pork.

Place the top bun and press gently. Serve each sandwich with a portion of fries on the side and extra BBQ sauce for dipping.

Optional finishing: garnish fries with chopped parsley or serve with coleslaw on the side for additional texture and acidity.