If brisket had a laid-back little cousin, this sbeef chuck roast on pellet grill would be it.
Big on flavor, low on fuss—and perfect for anyone who wants that smoky, tender BBQ vibe without babysitting a fire pit all day.
I made this beef chuck roast on my pellet grill last summer for a backyard birthday party (read: a dozen hungry kids and at least five adults “just tasting” before dinner). It was a total hit. I didn’t have to wake up at 5 a.m. to get a brisket going, and still ended up with melt-in-your-mouth, smoky slices that vanished in minutes. Even my neighbor—who never strays from brisket—asked for the recipe.
So let’s talk beef chuck roast on a pellet grill. Maybe you’ve been curious. Maybe there’s one hanging out in your freezer. Or maybe you’re just tired of the same-old dinner routine and need a new hero cut of meat. Either way, you’re in the right place.
This recipe gives you all the deep, smoky goodness of traditional barbecue, but with a cut that’s budget-friendly, super forgiving, and easy enough for a weeknight win. And yes—you can totally pass this off as a “chuck roast brisket” if you’re feeding a crowd. (Your secret’s safe with me.)
Let’s get into it!
Table of Contents
Why You’ll Love This Beef Chuck Roast on a Pellet Grill
- All the brisket feels, half the stress. Chuck roast is marbled, meaty, and magical when smoked low and slow.
- Prep it the night before, set it, and forget it. Well, almost. A few check-ins and you’re golden.
- Perfect for meal prep or a casual backyard hang. Sliced, chopped, or shredded—this roast does it all.
- Big flavor with pantry ingredients. Coffee + brown sugar + chili powder = chef’s kiss.
Ingredients
Here’s what you’ll need for your smoked beef roast:
- 3 small boneless chuck roasts (about 2 1/4 pounds each)
- 1/4 cup yellow mustard (optional—just helps the rub stick)
- Dry Rub:
- 2 tablespoons kosher salt
- 2 tablespoons black pepper
- 2 tablespoons chili powder (ancho or guajillo if you can find it)
- 2 tablespoons dark brown sugar
- 2 tablespoons ground coffee
- 1 tablespoon garlic powder
- 1 tablespoon onion powder
Step-by-Step Instructions
1. Mix your rub.
In a big bowl, whisk together the salt, pepper, chili powder, sugar, coffee, garlic, and onion powder. Try not to taste it with your finger… okay, maybe just a little.
2. Coat the roasts.
Brush each roast with mustard if you’re using it. Then, press that dry rub into every nook and cranny. Get those sides!
3. Let the flavor sink in.
Pop the seasoned roasts on a wire rack over a baking sheet. Let them hang out in the fridge for at least 8 hours—overnight is even better. This helps develop flavor and dries out the surface a bit for a better bark.
4. Fire up your pellet grill.
Preheat your smoker to 250ºF with the lid closed. Give it 15 minutes to come to temp.
5. Time to smoke.
Place the roasts directly on the grates. Smoke for 3–4 hours, until the internal temp hits between 155ºF and 165ºF. A nice dark bark should be forming by now—your kitchen will smell amazing.
6. Wrap it up.
Wrap each roast tightly in butcher paper or heavy-duty foil. This locks in the juices for the final stretch.
7. Back on the smoker.
Return the wrapped roasts and continue smoking for another 2–3 hours, or until the internal temp reaches 203ºF to 205ºF. That’s when the magic happens.
8. Let it rest.
Place the wrapped roasts in a cooler (no ice!) or a warm oven. Let them rest for 30–60 minutes so the juices redistribute.
9. Slice, chop, or shred.
However you serve it, you’re about to have a fan favorite on your hands.
Tips & Tricks
- No mustard? Use olive oil or even mayo as a binder—it won’t taste like mayo, promise.
- Short on time? Season the roasts in the morning and skip the overnight chill. You’ll still get great flavor.
- Want extra bark? After wrapping, unwrap for the last 30 minutes and crank the temp to 275°F.
- Serving idea: Load it onto buns with pickles and slaw, or pile it high next to mac & cheese.
FAQs of beef chuck roast on pellet grill
Can I make this ahead of time?
Yes! It actually tastes better the next day. Just slice or shred and reheat with a splash of beef broth.
Can I freeze leftovers?
Absolutely. Freeze in portions with the juices for up to 3 months.
What’s the best wood for smoking chuck roast?
I love a blend of hickory and cherry for that classic BBQ flavor, but oak or pecan are great too.
Do I have to use three roasts?
Not at all! One or two work just fine—just adjust your cook time slightly.
Is this like brisket?
Kinda! Chuck roast has similar marbling and tenderness when smoked right. It’s like brisket’s weeknight twin.
Smoked Beef Chuck Roast on a Pellet Grill
Equipment
- Pellet Grill
- Wire Rack
- Baking Sheet
- Butcher Paper or Foil
Ingredients
Beef Chuck Roast
- 3 boneless beef chuck roasts about 2¼ lbs each
- 1/4 cup yellow mustard optional, as binder
Dry Rub
- 2 tbsp kosher salt
- 2 tbsp black pepper
- 2 tbsp chili powder preferably ancho or guajillo
- 2 tbsp dark brown sugar
- 2 tbsp ground coffee
- 1 tbsp garlic powder
- 1 tbsp onion powder
Instructions
- Combine all dry rub ingredients in a bowl and mix well.
- Coat each roast with yellow mustard (if using) and then apply the dry rub evenly.
- Place roasts on a wire rack over a baking sheet. Refrigerate for at least 8 hours or overnight.
- Preheat pellet grill to 250°F (121°C). Close the lid and allow to stabilize for 15 minutes.
- Smoke roasts directly on grill grates for 3–4 hours until internal temperature reaches 155°F–165°F.
- Wrap roasts tightly in butcher paper or foil and return to grill.
- Continue cooking for another 2–3 hours until internal temperature reaches 203°F–205°F.
- Rest wrapped roasts in a cooler or warm oven for 30–60 minutes before slicing or shredding.
