Smoked Pulled Pork Sandwich Recipe

Prepare the pork

Trim excess surface fat from the pork butt, leaving a thin fat cap for flavor. Pat the meat dry with paper towels.

Mix the rub: in a bowl combine kosher salt, coarse black pepper, paprika, brown sugar, garlic powder, onion powder and ground cumin. Stir to combine.

Apply binder and rub: spread yellow mustard over the entire surface of the pork (this helps the rub adhere). Generously coat the pork with the dry rub, pressing it into the meat.

Let rest: place the rubbed pork in the refrigerator, uncovered or loosely tented, for at least 2 hours or up to overnight to set the crust.

Preheat smoker: prepare your smoker to maintain a steady 225°F (107°C). Add hickory or apple wood chunks for smoke flavor and let it stabilize.

Smoke the pork: place pork fat-side up on the smoker grate. Insert a probe thermometer into the thickest part (avoid bone). Smoke until internal temperature reaches 195–203°F (90–95°C), about 1.5–2 hours per pound; for a 5 lb butt expect roughly 7–10 hours. Spritz with apple juice or cider every 60–90 minutes after the first 2–3 hours to maintain moisture and help bark formation.

Wrap (optional): when pork reaches around 160–165°F and has a nice dark bark, wrap it tightly in foil or butcher paper with 1/2 cup apple juice to speed through the stall. Return to smoker until 195–203°F.

Rest: remove pork from smoker and let rest, still wrapped, for 45–60 minutes. Reserve the drippings (cooking jus) and skim any excess fat; keep about 1/2 cup for mixing with sauce or moistening pulled pork.

Pull the pork: using two forks or meat claws, shred the pork into bite-sized strands. Remove any large chunks of fat or gristle. If desired, toss shredded pork with 1/2 cup reserved jus and 1/2 cup Chef's BBQ Sauce to moisten and flavor (reserve extra sauce for serving).

Combine sauce ingredients: in a small saucepan add ketchup, apple cider vinegar, brown sugar, molasses, Worcestershire, hot sauce, smoked paprika, salt and black pepper.

Simmer: set saucepan over medium-low heat, stir to combine and bring to a gentle simmer. Reduce heat and simmer 8–12 minutes, stirring occasionally, until slightly thickened.

Finish with butter: remove from heat and whisk in 1 tablespoon butter for sheen and roundness. Taste and adjust sweetness, acidity or heat as needed. Keep warm or refrigerate until assembly; reheat gently before tossing with pork.

Make dressing: in a bowl whisk together mayonnaise, apple cider vinegar, Dijon mustard, sugar, celery seed, salt and black pepper until smooth.

Combine slaw: in a large bowl toss shredded green cabbage, red cabbage and carrot. Pour dressing over vegetables and toss until evenly coated.

Chill: cover and refrigerate for at least 30 minutes to let flavors meld. Taste before serving and adjust salt or vinegar if needed.

Toast buns: heat a skillet or griddle over medium heat. Spread butter on cut sides of potato buns and toast, buttered side down, until golden and crisp, about 1–2 minutes.

Warm pork and sauce: reheat pulled pork gently in a pan with reserved jus and additional Chef's BBQ Sauce if desired—warm through until steaming but not dried out.

Assemble sandwiches: place a generous portion (about 1/2 cup) of pulled pork on the bottom bun. Spoon a tablespoon or two of Chef's BBQ Sauce over the pork if not already mixed. Top with a heaping 1/4–1/3 cup creamy slaw, then add 3–4 Grillo's pickle slices.

Finish: place the toasted top bun on the sandwich. Serve immediately with extra BBQ sauce on the side and additional pickles if desired.

Yield: makes 8 sandwiches. Store leftover pulled pork refrigerated up to 4 days, sauce separately up to 1 week, and slaw up to 2 days.