Boston butt on a burger is a weekend projects that pays off in a way that’s hard to explain until you’ve eaten one. Smoked low and slow with hickory and a coffee-forward rub, then pulled and stacked on a bun with balsamic BBQ sauce. This is not a fast dinner and it’s not supposed to be. The overnight rest in the rub matters; the meat seasons from the inside out. You need charcoal for the smoke setup, a couple of aluminum pans, and apple cider vinegar for the mop. Everything else is patience and attention. Pull it when it shreds easily and the bark is set.
How to Make Smoked Boston Butt BBQ Burger
The coffee rub
Ground coffee mixed with your BBQ rub goes on the butt the night before. Don’t coat it entirely, just season with intention. The coffee deepens the bark without tasting like espresso in the finished meat.
Setting up the smoke
Char the charcoal bricks first, then move them to a pan away from direct heat. Add soaked hickory chips for steady, cool smoke. You want temperature around 225-250°F and consistent smoke, not flames.
Pulling and building
Rest the meat before pulling. Shred it coarsely, toss with the mustard and BBQ sauce mixture, and pile high on the bun. Extra sauce on the side. No napkins will survive this.
Smoked Boston Butt BBQ Burger
- Total Time: 375 minutes
- Yield: Serves 4
- Diet: Omnivore
Description
Juicy, smoky, and full of flavor, this BBQ burger is everything a great barbecue should be. Perfect for a weekend cookout.
Ingredients
- 3 lbs (1361 g) Boston Butt
- 2 tbsp ground coffee
- BBQ Rub
- Hickory wood chips
- charcoal
- 2 aluminum pans
- 1/4 cup apple cider vinegar
- 1 tbsp mustard
- 4 tbsp BBQ Sauce
- Extra BBQ Sauce
- Buns
Instructions
- Cut the twine off of the boston butt and discard.
- Mix together ground coffee and rub to season the butt, but do not coat it entirely.
- Place the butt on plastic wrap, season it, and wrap it up.
- Let the wrapped meat sit in the fridge overnight or for a few hours.
- Turn on the gas grill to high heat.
- Place 6-7 charcoal bricks on the grill to char until gray, flipping to get both sides warmed.
- Place about a cup of wood chips in a bowl of water to soak while the charcoal heats.
- Drain the wood chips before using.
- Place the hot charcoal in an aluminum pan and the wood chips over it on the grill.
- Place another aluminum pan with a quarter cup of water under the upper rack to catch drippings.
- Remove the plastic wrap from the boston butt and discard.
- Lightly grease the grill and place the butt on the upper rack.
- Set the grill temperature to 250°F (121°C) to maintain wood chip smoke.
- Grill for roughly 6 hours or until the internal temperature reaches 175-180°F (79-82°C).
- Mix together apple cider vinegar, mustard, and BBQ sauce for basting.
- Lightly brush the basting mixture over the meat every hour and a half, turning the meat.
- Check and refill the water pan as needed.
- Once cooked, let the meat sit for 15 minutes.
- Shred/slice the meat and add BBQ sauce.
Notes
- For a deeper smoke flavor, soak the hickory wood chips in apple cider vinegar for 30 minutes before grilling.
- If you don’t have hickory wood chips, you can substitute pecan or mesquite wood chips.
- Store leftover pulled pork in an airtight container in the refrigerator for up to 4 days; freeze for longer storage.
- Prep Time: 15 minutes
- Cook Time: 360 minutes
- Category: Main Course
- Method: Smoking
- Cuisine: American
Nutrition
- Serving Size: 1 burger
- Calories: 500
- Sugar: 15
- Sodium: 800
- Fat: 30
- Saturated Fat: 10
- Unsaturated Fat: 15
- Carbohydrates: 40
- Fiber: 5
- Protein: 40
- Cholesterol: 100
Frequently Asked Questions
Why use ground coffee in the rub?
Ground coffee adds a deep, roasted bitterness that balances the sweetness of BBQ sauce and enhances the smoky flavor from the hickory chips. Use a medium grind for even coating.
Can I smoke the Boston butt in a regular charcoal grill?
Yes. Set up a two-zone fire with charcoal on one side and the meat on the other. Keep the lid on and maintain low heat. Add soaked hickory chips to the coals every 30 to 45 minutes.
How do I know when the pork is done?
The meat should be tender enough to pull apart easily with a fork, typically after about 6 hours of smoking. Internal temperature should reach around 200°F (93°C).
