Smoky BBQ Pulled Pork Sandwich Recipe

Tender, slow-roasted pulled pork dripping in a rich, smoky BBQ sauce, served on a toasted brioche bun with crispy coleslaw.

⏱️

PREP20 mins

⏰

TOTAL8 hrs 20 mins

🍽️

SERVES8

🔥

CAL/SERVE580

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There is nothing quite like a classic, authentic Smoky BBQ Pulled Pork Sandwich. For barbecue lovers, achieving that melt-in-your-mouth tenderness with a deep, wood-fired smoke flavor is the ultimate goal. Whether you are cooking a whole hog or a simple pork shoulder roast, the magic happens low and slow.

This recipe will guide you through creating the perfect smoked pulled pork, slathered in a tangy homemade BBQ sauce, and piled high on a buttery toasted bun.

Why This Smoky BBQ Pulled Pork Sandwich Recipe Outshines the Rest

Incredible Smoky Flavor: The homemade rub and slow roasting process infuse the pork with an unbeatable authentic BBQ taste.
Perfect for Crowds: A single pork shoulder yields enough tender meat to feed a hungry crowd, making it ideal for summer cookouts or game day.
Customizable Sauce: You can easily adjust the BBQ sauce to be sweeter, tangier, or spicier according to your preference.

💡 Pro Tips for the Best Results

Use Bone-In Pork

A bone-in pork shoulder (Boston butt) yields the most tender and flavorful meat. The bone acts as a conductor of heat and helps you know when it's done-it should pull out completely clean.

Don't Skip the Rest

Resting the meat is crucial. If you shred it immediately, all the juices will run out, leaving you with dry pulled pork.

Smoky BBQ Pulled Pork Sandwich Recipe

By: Chef John

Category: Dinner

Difficulty: Easy

Cuisine: American BBQ

Yield: 8

Ingredients

01
4-5 lbs bone-in pork shoulder (Boston butt)
02
1/4 cup brown sugar
03
2 tbsp smoked paprika
04
1 tbsp kosher salt
05
1 tbsp black pepper
06
1 tbsp garlic powder
07
1 tsp cayenne pepper (optional)
08
1/2 cup apple cider vinegar (for spritzing)
09
2 cups your favorite smoky BBQ sauce (or homemade)
10
8 brioche buns
11
2 cups coleslaw (for topping)

Tools You'll Need

Smoker, Slow Cooker, or Dutch Oven
Meat Thermometer
Meat Claws or Forks
Spray Bottle (for spritzing)

Instructions

Step 01
Prepare the Pork Rub: In a small bowl, mix together the brown sugar, smoked paprika, kosher salt, black pepper, garlic powder, and cayenne pepper to create your dry rub.
Step 02
Season the Meat: Pat the pork shoulder dry with paper towels. Generously coat the entire roast with the dry rub, pressing it into the meat so it adheres well. For best results, wrap in plastic wrap and refrigerate overnight, but you can proceed immediately if short on time.
Step 03
Preheat Smoker or Oven: Preheat your smoker or slow cooker/oven to 250°F (120°C). If using a smoker, add hickory or applewood chunks for that authentic smoke flavor.
Step 04
Slow Roast: Place the pork shoulder in the smoker or oven. Cook low and slow for about 6 to 8 hours. Spritz the pork with apple cider vinegar every hour after the first 3 hours to keep the bark from drying out.
Step 05
Rest and Shred: Once the internal temperature reaches 200-205°F (93-96°C), remove the pork. Tent loosely with foil and let it rest for at least 45 minutes. Use two forks or meat claws to shred the pork, discarding any large pieces of fat or bone.
Step 06
Sauce and Assemble: Toss the shredded pork with 1 cup of the BBQ sauce, adding more if desired. Toast the brioche buns, pile high with the pulled pork, and top with fresh coleslaw.

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Frequently Asked Questions

How to make a smoky pulled pork sandwich recipe in a slow cooker?

To make it in a slow cooker, rub the pork as directed, place it in the slow cooker with a 1/2 cup of apple cider vinegar or broth, and cook on LOW for 8-10 hours until tender. Add a teaspoon of liquid smoke to mimic the smoker flavor.

What is the best smoked pulled pork BBQ sauce recipe?

A classic sweet and tangy sauce works best. Combine ketchup, apple cider vinegar, brown sugar, molasses, mustard, and a dash of liquid smoke. Simmer for 15 minutes to let the flavors meld.

How to BBQ right for smoked pulled pork?

The key to BBQing right is temperature control. Maintain a steady 225°F - 250°F in your smoker, use fruit woods like apple or cherry, and always cook to temperature (200°F+ internal), not by time.

Written by Chef John

John is a certified nutritionist and former restaurant head chef. He shares healthy, weeknight-friendly meals that don't compromise on flavor.

View all recipes by John ➔

Comments & Reviews

4.8 (125 Ratings)

Smoky BBQ Pulled Pork Sandwich Recipe

Why This Smoky BBQ Pulled Pork Sandwich Recipe Outshines the Rest