Smoked Boston Butt Roast on a Gas Grill

The Best Boston Butt Roast

One of my all time favorite recipes is pulled pork and my go to recipe is normally Kalua Pork but if you’ve ever had a Smoked Boston Butt Roast, you know it’s amazing. I’ve got a really great rub to share with you and, for those that don’t have a smoker, I’m going to teach you how to smoke your butt’s on a gas grill and still get the same results.

What is a Boston Butt

Some people confuse and automatically assume that a Boston Butt Roast is exactly what it sounds like, the butt or bottom muscle of the pig, but this couldn’t be further from the truth. It’s actually the front shoulder above another famous roast portion, the picnic. So, the difference is, the Butt roast is more square and has the shoulder blade bone cut into each portion and the picnic is more like the bicep and forearm(ham hocks) of the front legs. Both cuts of meat, however, make excellent pulled pork.

Apparently, butts are named after the barrels the pork was stored in during the revolutionary war in New England. The barrels themselves were indeed called butts. New England is comprised of six states in the northeastern united states and Boston Massachusetts is considered it’s largest city, Hence, the Boston Butt.

Seasoning a Pork Butt

There are many different ways to prepare a Smoked Boston Butt and no one recipe is the right way. When I think of pork roasts, though, I tend to lean towards my Latin taste buds which pull me towards a spicier more flavorful seasoning. Sure you could go with a classic salt and pepper rub and you would, most likely, get fantastic results. Me, on the other hand, prefer Barbacoa and Chipotle style recipes so, I put together a rub with a little more flare. I use yellow mustard as a binder and several sweet and savory ingredients for color and flavor.

You also have to consider whether or not you want to add any Barbecue Sauce. If you do want to add it, it’s best to brush a thin layer over the roast at the time of wrapping in foil. It’s also fairly common to unwrap the butt, when it’s done cooking, and glaze it with a thinner sauce. Common glaze’s are generally a mix of barbecue sauce, apple juice, apple cider vinegar and sometimes blended fruits like apricots or peaches. Once a glaze is applied, the Boston Butt Roast is placed back on the grill, uncovered, for 15-20 minutes to caramelize.

Smoking on a gas grill

Thanks to cooking shows on TV and cooking channels, like mine, on YouTube, Barbecue and smoked meats have gained extraordinary popularity. I think that most folks already love a good BBQ but, I’m not really sure that everyone has ever really experienced great barbecue. It was years before I ever really appreciated it. Any meat that came out of my Mom’s kitchen was never grilled and it always chewed like leather or an old shoe. Sadly, other than fish, I had no idea that meat could melt into your mouth until I was literally a full grown man. I quickly learned that slow and low is the way to go, for juicy, tender bites.

On a gas grill, unless someone is burning the food, there isn’t the luxury of smoke. Without the added flavors, that burning logs, chips, pellets and nitrates the smoke provides, you’re not going to get that infamous “smoke ring” grill masters brag about. The smoke, however, on a gas grill, can still be achieved and I show you how to do it in this video tutorial. What I don’t mention, though, is an alternative.

Getting Started

To achieve smoke, all you have to do is burn wood chips or pellets inside the barbecue grill itself. I purchased a cheap Smoker Tube from amazon that easily fills with pellets and accomplishes this task. You can, however just wrap wood chips or smoking pellets in a hand made aluminum foil pouch. Then poke holes in the foil to get the same if not similar results.

The Boston Pork Butt must cook over indirect heat. This means that there mustn’t be a gas burner directly under the meat. My grill, for example has 3 burners. I turn the front one on low and leave the back two off to place the butt over indirect heat. I also add a bowl of water, to regulate humidity and help to keep the roast from drying out. Another step you can take is spritzing the roast. I do this once every hour, with apple juice or apple cider vinegar. You can even mix the two together in a spray bottle if you want.

Time and Temperatures

I try to maintain a grill temperature around 275° F on my lowest setting. On hotter days, sometimes the grill will heat up as high as 325° F so, don’t freak out if yours does. The look of the outside and the actual internal temp of the pork butt is what really matters. Still, if possible, try to lower, control and maintain the lower temp of 275° F.

The smoker tube, on average, lasts 2 to 3 hours before more wood chips or pellets need to be added. I only add them once. When the tube burns out the second time, there’s no need for further smoke.

When to Wrap your Roast

I probe the center of the roast with a thermometer after 4 hours. Once I’ve reached 160° F internal temp, I wrap the Boston Butt in foil and roast until internal temperature reaches 195° F. Then I remove it from the grill and let it rest 20 to 30 minutes before I shred it.

If I wrapped the the butt properly, there won’t be any leakage. There will be a puddle of roast juice in the bottom of the foil when I unwrap it. This juice or Au Jus, if you will, is essential for the pulled pork to reach maximum flavor. It also provides a ton of moisture in the meat. This keeps it from drying out so, don’t throw it out. Just poor the whole thing over the shredded pulled pork and turn the pieces over a few times before serving.

If you’re interested in making pulled pork sandwich’s with this recipe, check out my Coleslaw recipe.

More Related Recipes

Smoked Spare Ribs, Country-style Barbecue Ribs, Baby Back Ribs Foil Dinner, Barbecue Spare Ribs. Oven Baked Ribs, Kalua Pork Roast, Pork Barbacoa, Braised Pork Belly with Noodles, Beef Short Ribs with Gravy. Smoked Country-style Boneless Beef Ribs, Braised Beef Short Ribs, Mongolian Beef Ribs. Northern-style Pork Ribs, Smoked Beef Rib Roast, Picanha, Roasted Bone Marrow, Mexican Street Corn (Elota). Mac Salad, Spaghetti Salad, Seared Pepper Salad, Fresh Veggies with Ricotta Mint & Lime.

Smoked Boston Pork Butt Ingredients:

• 7.5 lbs Boston Pork Butt — average sized pork shoulder
• 3 tbsp Yellow Mustard — used as a binder

Pork But Rub

• ½ cup Smoked Paprika – Adds deep, smoky flavor and rich color.
• 3 tbsp Kosher Salt – Enhances the taste and helps with moisture retention.
• 2 tbsp Black Pepper – Gives a bold, peppery kick.
• 2 tbsp Brown Sugar – Balances the seasoning with a touch of sweetness.
• 2 tbsp Cumin – Brings warm, earthy notes to the rub.
• 1 tbsp Coffee Grains – Adds a subtle depth and richness.
• 1 tsp Garlic Powder – Provides a savory, garlicky boost.
• 1 tsp Onion Powder – Rounds out the flavors with mild sweetness.

Spritzing the Roast

• Apple Cider Vinegar – Used for spritzing to keep the meat moist and flavorful.

Instructions

1. Prep the Meat: Pat the Boston Butt dry with paper towels. Trim any excess fat, leaving about ¼ inch for moisture and flavor.
2. Season Generously: In a bowl, mix smoked paprika, kosher salt, black pepper, brown sugar, cumin, coffee grains, garlic powder, and onion powder. Rub the entire roast generously, making sure to coat all sides. Let it sit at room temperature for about 30 minutes to allow the seasoning to adhere.
3. Set Up the Gas Grill for Indirect Smoking:
   • Preheat the grill to 250°F with only one side of the burners on.
   • Place a foil pan filled with water on the indirect side to help maintain moisture.
   • Add wood chips (hickory, apple, or pecan) in a smoker box or wrapped in foil with holes poked in it, placing it over the lit burner.
4. Start Smoking: Place the seasoned Boston Butt on the grill over indirect heat, fat side up. Close the lid and let it smoke for about 4-5 hours, maintaining a steady 250°F.
5. Spritz for Moisture: Every hour, spritz the roast lightly with apple cider vinegar to enhance the bark and keep it from drying out.
6. Wrap at the Stall: Around 165°F internal temp, the meat will hit the “stall” (where it stops rising in temperature). At this point, wrap it tightly in butcher paper or aluminum foil to speed up cooking and retain moisture.
7. Finish Cooking: Place the wrapped roast back on the grill and continue smoking until it reaches an internal temperature of 200-205°F, about 3-4 more hours.
8. Rest Before Serving: Remove the roast from the grill, keep it wrapped, and let it rest for at least 30-60 minutes. This allows the juices to redistribute for maximum tenderness.
9. Shred and Serve: Unwrap the roast and shred it with two forks or meat claws. Add the leftover juice from the roast and serve. For more flavor, shake the rub seasoning into the shredded pulled pork.

Be sure to watch the short video tutorial and I’ll show you exactly how to smoke your butt roast to perfection.

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Grills, Meat Smokers, Barbecue Equipment, Dry Aging Meat Coolers, Meat Rubs, Butcher Paper