How to Cook a Boston Butt on a Charcoal Grill

Cooking a Boston butt on a charcoal grill is a time-honored tradition for barbecue lovers. This cut, rich with fat and flavor, transforms into tender, pull-apart pork when cooked low and slow over charcoal and wood. If you’ve ever wondered how pitmasters turn this tough cut into smoky, succulent goodness, this guide has you covered from prep to plate.

Boston butt, despite the name, doesn’t come from the rear of the pig. It’s a beautifully marbled section from the upper shoulder. When treated with time, smoke, and patience, it becomes one of the most rewarding cuts to cook on a charcoal grill.

Grilling with charcoal offers unmatched flavor and gives you full control over the smoking process. While gas grills are more convenient, nothing matches the authenticity of a well-smoked Boston butt cooked over glowing coals and flavored wood.

This article walks you through every step to create mouthwatering pulled pork using your charcoal grill. Whether you’re new to low-and-slow cooking or looking to improve your BBQ game, you’re in the right place.

Understanding the Boston Butt

What Is It?

Boston butt, also called pork butt or pork shoulder, comes from the top portion of the pig’s front shoulder. It includes a good amount of intramuscular fat, making it perfect for slow cooking.

Bone-in vs. Boneless

Both options work, but bone-in is ideal. The bone adds flavor and helps the meat cook evenly. Boneless is easier to carve and may cook a bit faster, but many purists prefer the bone-in experience.

Ideal Size

A Boston butt typically weighs between 5 to 9 pounds. For charcoal grilling, a 6 to 8 lb bone-in cut is perfect it offers enough mass for a good smoke ring and bark development without being unwieldy.

Preparing the Grill for Indirect Cooking

To cook a Boston butt properly, you need to set your charcoal grill for indirect cooking, meaning the heat source is on one side and the meat is on the other.

Tools Needed:

• Charcoal grill (Weber Kettle works great)
• Chimney starter
• Charcoal briquettes or lump charcoal
• Wood chunks (applewood, hickory, or oak)
• Aluminum drip pan
• Meat thermometer (digital preferred)
• Heat-resistant gloves
• Grill tongs

Setting Up the Grill:

1. Use the Two-Zone Method: Push lit coals to one side of the grill, leaving the other side coal-free.
2. Place a Drip Pan: On the empty side, set a drip pan filled halfway with water. It catches drippings and helps stabilize grill temperature.
3. Add Smoking Wood: Place 2–3 wood chunks (not soaked) on the hot coals.
4. Control Temperature: Close the grill lid with the air vent over the meat. Adjust the bottom and top vents to maintain a cooking temp between 225°F and 250°F.

Pro Tip: Keep a thermometer probe on the grill grate next to the butt for accurate temp readings.

Prepping the Boston Butt

Trim the Fat (Optional)

You can remove thick fat caps over ¼ inch, but leave some fat for flavor. Trimming also allows your rub to penetrate the meat more thoroughly.

Bind with Mustard or Oil

Coat the entire surface of the butt with yellow mustard or olive oil. This helps the rub stick and contributes to bark development.

Apply the Dry Rub

Use a generous layer of seasoning. You can buy a store-bought rub or make your own:

DIY Rub Recipe:

• ¼ cup brown sugar
• 2 tbsp paprika
• 1 tbsp kosher salt
• 1 tbsp black pepper
• 1 tsp garlic powder
• 1 tsp onion powder
• ½ tsp cayenne (optional for heat)

Massage the rub into every crevice. Wrap the butt in plastic wrap and refrigerate overnight for best results, or let it sit at room temperature for 1 hour before grilling.

Grilling Process: Low and Slow

Place on the Grill

Position the Boston butt fat side up on the indirect side of the grill, above the drip pan. Close the lid and monitor the temperature.

Maintain a Steady Heat

Keep your grill between 225°F–250°F. Add a few unlit coals and another wood chunk every 60–90 minutes to sustain heat and smoke.

Spritz to Keep Moist

After 2–3 hours, begin spritzing the meat every 45–60 minutes. Use a mixture of:

• 1 cup apple cider vinegar
• 1 cup apple juice
• Optional: A splash of bourbon or hot sauce

Spritzing adds moisture, enhances bark, and infuses subtle tanginess.

Cooking Time

Estimate 1.5 to 2 hours per pound. A 7-pound butt may take 10–12 hours. Let the internal temperature be your guide, not the clock.

Monitoring Temperature

A reliable meat thermometer is essential.

Target Internal Temperatures:

• 160°F: The stall begins (where the internal temp plateaus).
• 160–170°F: Wrap the meat in foil or butcher paper if desired.
• 195–205°F: Ready for pulling. At this point, the meat should feel like softened butter when probed.

Avoid peeking too often—each lid opening drops the temp and extends the cook time.

Resting and Pulling the Meat

Let It Rest

After the butt reaches the target temp, remove it from the grill and wrap in foil. Rest it in a cooler or wrapped in towels on the counter for at least 30–60 minutes. This redistributes the juices and makes pulling easier.

Pull the Pork

Use two forks, heat-proof gloves, or meat claws. Shred the meat, discard large fat pockets, and remove the bone it should slide out cleanly.

Mix in the juices collected in the foil for extra flavor. Add a touch more seasoning or a bit of finishing sauce if you’d like.

Serving Suggestions

Sandwiches

Classic pulled pork sandwiches with soft buns, tangy BBQ sauce, and coleslaw never fail.

Tacos

Toss the pulled pork with lime juice, pile into corn tortillas, and top with pickled onions and avocado.

Platter Style

Serve with:

• Coleslaw
• Baked beans
• Mac and cheese
• Pickles
• Cornbread

Sauce Ideas:

• Carolina vinegar-based sauce for tang
• Kansas City sweet BBQ for richness
• Mustard-based sauce for something different

Serve on the side so guests can choose their flavor.

Tips and Troubleshooting

Grill Temperature Spikes?

• Close the bottom vents partially to reduce oxygen.
• Add a pan of water to stabilize the heat.

Temp Drops Too Low?

• Add more lit charcoal using tongs.
• Open bottom vents to increase airflow.

Pork is Dry?

• It was likely overcooked or rested too long unwrapped.
• Mix in a bit of broth or apple juice when pulling.

Bark Too Soft or Burnt?

• Don’t wrap too early or too late.
• Avoid overusing sugar in your rub, which can burn.

The Stall Scare You?

• It’s normal. Be patient, or wrap with butcher paper to power through it.

Conclusion

Cooking a Boston butt on a charcoal grill is a rewarding experience that brings flavor, aroma, and satisfaction to your backyard BBQ. The process is simple but requires time, attention, and a little know-how.

Start with a quality cut, prepare your grill for indirect cooking, season well, smoke low and slow, and be patient through the stall. Rest the meat, pull it tender, and serve it up with pride.

Once you’ve mastered this, you’ll be the go-to grill master at every gathering. So fire up that charcoal, grab a cold drink, and let your Boston butt do the talking.