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Smoked Pulled Pork Chili

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This Smoked Pulled Pork Chili is the ultimate comfort food, combining the rich smokiness of slow-cooked pork with a bold, hearty chili base. Perfect for game day, cold nights, or any time you need a filling, flavorful meal.

Ingredients

Scale

For the Smoked Pulled Pork:

  • 45 lb pork shoulder (Boston butt)
  • 2 tbsp olive oil
  • 2 tbsp chili powder
  • 1 tbsp smoked paprika
  • 1 tbsp garlic powder
  • 1 tbsp onion powder
  • 1 tbsp cumin
  • 2 tsp kosher salt
  • 1 tsp black pepper
  • ½ cup apple cider vinegar
  • Wood pellets (hickory or mesquite recommended)

For the Chili Base:

  • 2 tbsp butter or oil
  • 1 large onion, diced
  • 1 red bell pepper, diced
  • 3 cloves garlic, minced
  • 1 can (28 oz) fire-roasted diced tomatoes
  • 1 can (15 oz) tomato sauce
  • 2 cups beef broth
  • 1 can (15 oz) kidney beans, drained (optional)
  • 1 can (15 oz) black beans, drained (optional)
  • 1 tbsp Worcestershire sauce
  • 2 tbsp tomato paste
  • 1 tbsp hot sauce (optional)
  • 1 tbsp brown sugar
  • 2 tbsp chili powder
  • 1 tsp smoked paprika
  • 1 tsp ground cumin
  • ½ tsp ground cayenne (optional for heat)
  • Salt and black pepper to taste

Instructions

1. Smoke the Pork Shoulder:

  1. Preheat your Traeger or pellet smoker to 225°F.
  2. Rub the pork shoulder with olive oil and coat evenly with chili powder, smoked paprika, garlic powder, onion powder, cumin, salt, and black pepper.
  3. Place the pork on the smoker and smoke for 4-5 hours, or until it reaches an internal temp of 165°F.
  4. Wrap the pork in foil, add ½ cup apple cider vinegar, and continue smoking until the internal temp reaches 200-205°F (another 3-4 hours).
  5. Remove from the smoker, let rest for 30 minutes, then shred the pork with forks.

2. Cook the Chili Base:

  1. Heat butter or oil in a large Dutch oven or pot over medium heat.
  2. Sauté onions and bell peppers for 5 minutes until softened.
  3. Add garlic and cook for 30 seconds until fragrant.
  4. Stir in tomato paste, diced tomatoes, tomato sauce, Worcestershire sauce, and beef broth.
  5. Add pulled pork, chili powder, smoked paprika, cumin, cayenne, and brown sugar. Stir well.
  6. Simmer for 1-2 hours, stirring occasionally. Add water if it thickens too much.

3. Serve & Enjoy!

  • Ladle into bowls and top with shredded cheese, sour cream, jalapeños, or green onions.
  • Serve with cornbread, tortilla chips, or rice.

Notes

  • Prefer it extra spicy? Add extra cayenne or diced jalapeños.
  • No smoker? Use pre-cooked pulled pork and add 1 tsp liquid smoke to the chili base.
  • Leftovers? This chili tastes even better the next day! Store in the fridge for 3-4 days or freeze for up to 3 months.