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Boston butt, also known as pork butt or pork shoulder, is a favorite among BBQ lovers for its rich flavor, ample marbling, and incredible tenderness when cooked low and slow. One of the best ways to prepare this cut is by using a pellet grill, which delivers consistent heat and smoky flavor without the hassle of managing a fire.
In this guide, we’ll take you through every step of cooking Boston butt on a pellet grill from choosing the right cut to pulling it perfectly after hours of smoking. Whether you’re a weekend warrior or backyard pitmaster, this walkthrough will help you serve up a pork masterpiece.
Boston Butt and Pellet Grilling
Boston butt is cut from the upper part of the pig’s shoulder. Despite its name, it has nothing to do with the rear end of the pig. It’s loaded with connective tissue and fat, making it ideal for slow-cooking methods like smoking. When cooked properly, it becomes fork-tender and perfect for pulled pork.
Pellet grills simplify the smoking process. These grills use compressed hardwood pellets to generate heat and smoke, delivering consistent temperatures and excellent flavor. The combination of convenience and control makes them ideal for smoking large cuts like Boston butt.
Choosing the Right Boston Butt
Bone-in vs. Boneless
Bone-in Boston butts are often preferred for smoking due to their ability to retain moisture and enhance flavor. The bone also acts as a natural thermometer—when it wiggles easily, your meat is ready.
Boneless cuts cook faster and are easier to portion and serve, but may be slightly drier if overcooked.
Ideal Size
A 6–10 lb Boston butt is the sweet spot for home smoking. This size allows for a full smoke without taking up your entire day. Expect about 40–50% yield after trimming and cooking.
What to Look For
- Color: Rich pink or reddish hues
- Marbling: Look for good intramuscular fat, which keeps the meat juicy
- Fat Cap: A nice layer of fat on one side helps baste the meat as it smokes
Pellet Grill Preparation
Choosing Wood Pellets
Your wood choice affects flavor dramatically. Here are a few popular options:
- Hickory: Strong and smoky; classic BBQ taste
- Apple: Mild and sweet; great with pork
- Cherry: Rich color and a subtly sweet flavor
- Maple: Balanced and smooth
Mixing pellets can give you a more complex flavor. A 50/50 mix of hickory and apple is a popular combo for pork.
Prepping the Grill
- Clean the burn pot and remove old ash for even burning.
- Fill the hopper with your chosen pellets.
- Place a drip pan under the grill grate to catch juices and prevent flare-ups.
- Use a water pan for added moisture, especially helpful in dry climates.
Set your grill to preheat at 225°F to 250°F before placing the meat inside.
Preparing the Boston But
Trimming the Fat
Trim any hard, excess fat, especially around the edges. Leave about 1/4 inch of the fat cap to keep the meat moist. Too much fat can prevent smoke from penetrating.
Using a Binder
While optional, binders help the rub adhere better. Try:
- Yellow mustard (most common)
- Olive oil
- Hot sauce for an extra kick
Dry Rub Recipe
You can use your favorite BBQ rub, or make this homemade blend:
Basic Pork Butt Rub:
- 1/4 cup brown sugar
- 2 tbsp paprika
- 1 tbsp salt
- 1 tbsp black pepper
- 1 tbsp garlic powder
- 1 tbsp onion powder
- 1 tsp cayenne (optional)
- 1 tsp mustard powder
Apply the rub generously on all sides and edges. Let it sit at room temperature for about 30–60 minutes, or refrigerate overnight for a deeper flavor.
Optional Injection
Injecting adds internal moisture and flavor. A simple pork injection:
- 1 cup apple juice
- 1/2 cup chicken broth
- 2 tbsp Worcestershire sauce
- 1 tsp salt
Use a meat injector to push the liquid deep into the meat every couple of inches.
Smoking Process on the Pellet Grill
Preheating
Set your pellet grill to 225°F. For a shorter cook time, you can go up to 250°F, but lower temps allow for more smoke absorption.
Placement
Place the pork butt on the grill grates, fat side up (most common), so the fat bastes the meat as it renders. Some prefer the fat side down if the heat source is underneath, to protect the meat from burning.
Monitoring Internal Temp
Insert a meat probe into the thickest part, avoiding the bone. Monitor throughout the cook.
Spritzing for Moisture
Spritz the pork every hour starting at the 2-hour mark using a spray bottle. Use:
- Apple juice
- Apple cider vinegar
- A mix of both
This helps maintain bark moisture and prevents it from drying out.
Bark Formation
The bark is the flavorful crust on the exterior formed by the rub and smoke. It’s a key part of great pulled pork. Avoid wrapping too early so the bark develops properly.
Wrapping the Pork Butt (Texas Crutch)
Once the internal temperature hits 160°F to 170°F, the meat may hit a “stall” where the temperature stops rising due to moisture evaporation.
Why Wrap?
Wrapping speeds up cooking and retains moisture.
Foil vs Butcher Paper
- Foil: Seals in moisture but can soften bark
- Butcher paper: More breathable, preserves bark texture better
Add a bit of liquid (apple juice, broth, or butter) before sealing.
Cooking to Final Temperature
Keep smoking the wrapped pork until it reaches an internal temp of 195°F to 205°F.
Signs of Doneness
- Bone wiggles freely (for bone-in)
- Probe slides in with no resistance, like softened butter
- The meat shrinks slightly from the bone
Estimated Cooking Time
Plan for 1.5 to 2 hours per pound, plus resting time. For an 8-lb Boston butt, you’re looking at 12–16 hours total.
Resting the Pork
Why Resting Matters
During the rest, juices redistribute throughout the meat, ensuring moist and tender pork.
How to Rest
- Leave the wrapped pork in a dry cooler with towels for 30 minutes to 1 hour
- Or rest in a warm oven set to 150°F (if a cooler isn’t available)
Never skip this step—it’s worth the wait.
Pulling and Serving the Boston Butt
How to Shred
Use:
- Meat claws
- Two forks
- Clean hands with gloves
Remove the bone and any large chunks of fat. Mix the meat well to evenly distribute bark and internal meat.
Mixing in Juices
Pour some of the reserved juices (from the wrap or drip pan) back into the pulled pork for added flavor. You can also add:
- A finishing rub
- Your favorite BBQ sauce
Serving Ideas
- Classic pulled pork sandwiches with coleslaw
- Pork tacos or nachos
- Over grits or baked potatoes
- With cornbread and greens
Tips, Troubleshooting & FAQs
The Stall Is Taking Forever!
Be patient or bump the temp to 275°F briefly. Wrapping will also help push through.
How Do I Get More Smoke Flavor?
Start at a lower temp (around 200°F) for the first few hours. Use stronger woods like hickory or mesquite. Avoid over-wrapping too early.
What if I Overshoot the Final Temp?
As long as you’re within 210°F, you can still salvage the meat. Shred it and mix with juices—it’ll still be delicious.
Can I Cook Overnight?
Yes! Pellet grills are ideal for overnight cooks. Make sure:
- The hopper is full
- The probe alarm is set
- You’re using a reliable grill model
Conclusion
Cooking Boston butt on a pellet grill is one of the most rewarding BBQ experiences. From selecting a well-marbled cut to layering flavors with rubs and smoke, and finally shredding tender, juicy pork, each step contributes to a meal that’s sure to impress.
With this guide, you now have the tools to create perfectly smoked pulled pork at home. Whether for a family cookout or a weekend BBQ feast, your Boston butt will be the star of the show.