Name: Old Canal Smoke Houses Hand-Pulled Pork Recipe
Cook time: 12 h
Total time: 12 h
Yield: 8 servings
Cuisine: American
Ingredients: 5 lbs pork butt (Boston butt), bone-in; 2 l water (for brine); 1 cup kosher salt (for brine); 1 cup brown sugar (for brine); 1 tbs whole black peppercorns; 3 each bay leaves; 6 each garlic cloves, smashed; 3 tbs paprika (sweet or smoked); 2 tbs dark brown sugar (packed); 2 tsp kosher salt; 1 tsp black pepper, ground; 1 tsp garlic powder; 1 tsp onion powder; 1 tsp ground cumin; 1 tsp chili powder; 1 tsp dry mustard; 1 cup apple cider vinegar; 1 cup apple juice; 3 each hickory wood chunks (or preferred smoking wood); 2 tbs unsalted butter, melted (optional, for moistening during rest); 1 cup barbecue sauce; 8 each hamburger buns; 1 cup pickles; 2 cups coleslaw

Method

Pork and Brine

Make brine

In a large pot, combine 2 liters of water, 1 cup kosher salt, 1 cup brown sugar, whole peppercorns, bay leaves, and smashed garlic. Heat gently, stirring until salt and sugar dissolve. Remove from heat and cool to room temperature, then chill in refrigerator until cold (at least 2 hours).

Brine pork

Place the 5 lb pork butt in a large nonreactive container or heavy-duty zip-top bag. Pour the cooled brine over the pork, ensuring it is fully submerged. Weigh down if needed. Refrigerate 8–12 hours (overnight) for best flavor and moisture. If short on time, 4 hours minimum.

Dry and rest

Remove pork from brine, discard brine, and pat pork very dry with paper towels. Place on a rack and refrigerate uncovered for 1–2 hours to dry the surface; this helps the rub adhere and forms a better bark.

Dry Rub

Prepare rub

Combine paprika, dark brown sugar, 2 tsp kosher salt, ground black pepper, garlic powder, onion powder, cumin, chili powder, and dry mustard in a small bowl and mix thoroughly.

Apply rub

Coat the pork butt evenly with the dry rub, massaging it into all exposed surfaces. Let the rubbed pork rest at room temperature 30–45 minutes while you prepare the smoker; this helps the rub adhere and the meat come closer to ambient temperature for even cooking.

Smoking and Basting

Prepare smoker

Preheat your smoker to a steady 225°F (107°C). Add hickory wood chunks (or your choice) to produce a moderate, steady smoke—avoid heavy, acrid smoke. If using a charcoal smoker, set up for indirect heat. Ensure a drip pan is in place under the grate where the pork will sit.

Start smoking

Place the pork butt fat-side up on the smoker grate over the drip pan. Insert a probe thermometer into the thickest part of the meat (not touching bone). Close the lid and maintain 225°F. Smoke until the internal temperature reaches about 160–165°F (71–74°C). This typically takes about 4–6 hours for a 5 lb roast but varies with smoker and conditions.

Baste periodically

Combine apple cider vinegar and apple juice in a spray bottle or small bowl. Every 45–60 minutes after the first 2 hours of smoking, lightly spritz or mop the exposed pork with the mixture to maintain moisture and add brightness. Do not over-saturate the surface; a light misting is sufficient.

Texas crutch (optional)

When the pork reaches 160–165°F and smoke color is deep, if you want to speed through the stall and keep moisture, wrap the pork tightly in two layers of heavy-duty foil or in parchment plus foil, adding 1/4 cup apple juice inside the wrap. Return to smoker and continue until internal temperature reaches 195–205°F (90–96°C). For a more pronounced bark, skip wrapping and continue unwrapped until temperature target is reached.

Finish smoking

Continue until the probe thermometer slides into the meat with little resistance and the internal temperature reads 195–205°F. For fall-off-the-bone tenderness, aim for the upper end (200–205°F). Total smoke time for a 5 lb butt is typically 8–12 hours depending on stall and wrapping choice.

Resting

Remove the pork from the smoker. If wrapped, keep it wrapped. Place in a cooler or oven (turned off) and let rest for at least 1 hour; up to 2 hours is fine. If unwrapped, tent loosely with foil and brush with melted butter if desired to add sheen and a touch of richness.

Shredding and Serving

Shred the pork

Unwrap the rested pork and transfer to a large cutting board or tray. Use two forks, meat claws, or gloved hands to pull the pork into shreds, removing and discarding large pieces of fat and the bone. Continue shredding until you reach the desired texture (large chunks or finely pulled).

Moisten and season

Reserve any juices from the drip pan or the foil packet and mix into the shredded pork a little at a time to moisten. If desired, stir in up to 1 cup barbecue sauce, or serve sauce on the side. Taste and adjust seasoning with a pinch of salt, pepper, or a splash of apple cider vinegar to brighten.

Serve

Pile the pulled pork on buns and top with pickles and coleslaw as desired. Keeps well in a sealed container refrigerated up to 4 days and freezes for up to 3 months.

Hand-pulled Pork Recipe