How Long to Cook a 10lb Boston Butt on the Grill: A Complete Guide

When it comes to barbecue, few cuts of meat are as beloved and rewarding as the Boston butt. This flavorful pork shoulder cut, when cooked correctly, becomes fall-apart tender, juicy, and smoky perfect for pulled pork sandwiches, tacos, or a hearty BBQ platter. But when dealing with a 10lb Boston butt, timing is everything.

Cooking a large cut of meat on the grill requires patience, preparation, and precision. If you’re wondering how long to cook a 10lb Boston butt on the grill, the answer depends on several variables, including your grill setup, cooking temperature, and whether the butt is bone-in or boneless.

In this guide, we’ll cover everything you need to know from estimating cooking times to prepping the meat and mastering low-and-slow techniques that yield mouthwatering results.

What is a Boston Butt?

Despite the name, the Boston butt doesn’t come from the rear of the pig. It’s actually a cut from the upper portion of the pork shoulder, above the picnic shoulder. It typically includes a good amount of marbling, connective tissue, and sometimes the shoulder blade bone.

Why it’s great for BBQ:

• Rich marbling and fat content
• Becomes extremely tender when cooked low and slow
• Holds up well to dry rubs, marinades, and smoke
• Ideal for pulling or shredding

The term “Boston butt” originated from Colonial New England, where butchers would pack this inexpensive cut into barrels, called “butts,” for storage and transport. Over time, the name stuck.

Key Factors That Affect Cooking Time

When grilling a Boston butt, there’s no one-size-fits-all cook time. The following variables will affect how long it takes to cook your 10lb cut:

1. Grill Type

• Charcoal Grill: Requires manual temperature management, but imparts great smoky flavor.
• Gas Grill: Easier to control temps, but may require wood chips for smokiness.
• Pellet Grill/Smoker: Ideal for long cooks; maintains consistent temps and smoke flavor.

2. Cooking Temperature

• The standard for low-and-slow BBQ is 225°F to 250°F.
• Higher temps (275°F–300°F) speed things up but risk drying out the meat if not monitored carefully.

3. Bone-In vs. Boneless

• Bone-in cuts take slightly longer but tend to stay juicier.
• Boneless butts cook a bit faster but may dry out more easily without proper care.

4. Weather Conditions

• Wind, humidity, and ambient temperatures can impact how your grill holds heat, especially for charcoal or offset smokers.

5. Resting Time

• After grilling, resting is essential for allowing juices to redistribute. This adds to your total cook time but not your grill time.

General Time Estimate for a 10lb Boston Butt

The golden rule for smoking or grilling pork butt at 225°F is:

1.5 to 2 hours per pound

For a 10lb Boston butt:

• Low & slow (225°F) = 15–20 hours
• Moderate heat (275°F) = 10–12 hours
• High heat (300°F) = not recommended for the entire cook; may dry out

Remember: Temperature beats time. Always go by internal meat temperature rather than relying solely on the clock.

How to Prepare the Boston Butt

A great cook starts with thoughtful preparation. Here’s how to prep your pork for grilling greatness:

1. Trim Excess Fat

Leave a thin layer of fat for flavor, but trim thick fat caps (over ¼ inch) to avoid flare-ups and promote better bark formation.

2. Apply a Dry Rub

A dry rub creates the flavorful crust or “bark” on the exterior of the pork.

Classic BBQ Rub Recipe:

• ¼ cup brown sugar
• 1 tbsp paprika
• 1 tbsp smoked paprika
• 1 tbsp kosher salt
• 1 tsp garlic powder
• 1 tsp onion powder
• 1 tsp ground mustard
• ½ tsp black pepper
• Optional: cayenne pepper or chili powder for heat

Rub generously all over the pork. Let it sit for at least 30 minutes—or refrigerate overnight for deeper flavor.

3. Optional: Inject or Marinate

Inject with apple juice, apple cider vinegar, or a mix of broth and seasoning for added moisture. If marinating, do so overnight in a sealed container or bag.

4. Bring to Room Temperature

Before grilling, let the meat rest at room temp for 30–60 minutes. This helps it cook more evenly.

Setting Up the Grill for Low & Slow Cooking

1. Use the Indirect Heat Method

Whether using gas, charcoal, or pellets, your pork butt should be placed away from direct flames.

Charcoal Grill Setup:

• Bank coals to one side.
• Place a drip pan under the meat on the cool side.
• Add soaked wood chunks or chips on the coals.

Gas Grill Setup:

• Turn on only one or two burners (depending on size).
• Place pork on the unlit side with a water/drip pan underneath.

Pellet Grill Setup:

• Set your desired temp (225°F–250°F).
• Use hickory, applewood, or pecan pellets for best flavor.

2. Add Moisture

Place a water pan near the meat to help regulate grill humidity and keep the pork from drying out.

3. Maintain Temperature

Invest in a digital grill thermometer or probe. Opening the lid too often causes heat loss and extends cooking time.

Step-by-Step Instructions: Cooking a 10lb Boston Butt on the Grill

Step 1: Preheat the Grill

Aim for a consistent temperature of 225°F–250°F.

Step 2: Place the Pork on the Grill

Set it fat-side up over the indirect heat zone. This allows fat to render down through the meat.

Step 3: Close the Lid and Monitor

Cook with the lid closed. Check temperature hourly. Maintain smoke by adding wood chunks or chips every hour if needed.

Step 4: Spritz Every 60–90 Minutes

Use a spray bottle to mist the meat with:

• Apple cider vinegar
• Apple juice
• Beer or broth

This keeps the surface moist and helps build flavorful bark.

Step 5: Wrap During the Stall (Around 160°F)

At 155°F–165°F, the meat will “stall” as moisture evaporates. To power through:

• Wrap the pork tightly in butcher paper or aluminum foil
• This speeds up cooking and retains moisture

Step 6: Cook to 195°F–205°F Internal Temperature

• For pull-apart pork, shoot for 203°F
• For sliced pork, remove at 190°F–195°F
  Use a reliable instant-read thermometer to confirm.

Resting and Serving

Once your pork reaches the target internal temperature, remove it from the grill and let it rest.

Resting Process:

• Keep it wrapped
• Place in a cooler or on the counter
• Let rest for at least 1 hour, up to 2 hours

This step is crucial. It allows the juices to redistribute, making the meat tender and juicy.

Shredding the Pork

• Use two forks, meat claws, or clean hands
• Discard large fat deposits or bone
• Mix in juices collected in the wrap
• Add BBQ sauce (optional) and mix gently

Serving Suggestions

• Pulled Pork Sandwiches with slaw
• Tacos or burritos
• Pork sliders with pickles
• Serve with classic BBQ sides:
  • Baked beans
  • Potato salad
  • Macaroni and cheese
  • Grilled corn

Flavor Variations & Pro Tips

Flavor Boosters

• Inject before grilling with apple juice or Cajun butter
• Use mustard as a binder for the dry rub
• Add a final glaze of sweet BBQ sauce during the last 30 minutes

Wood Pairings

• Hickory: bold and classic
• Applewood: mild and sweet
• Pecan: slightly nutty and smooth
• Cherry: slightly fruity with a rich smoke

Bark Perfection Tips

• Don’t over-spritz early on
• Avoid wrapping too soon
• Let the rub form a dark, rich crust before wrapping

Common Pitfalls to Avoid

❌ Not Monitoring Grill Temp

Fluctuations can ruin your cook. Use a dual-probe thermometer.

❌ Opening the Lid Too Often

Every time you lift the lid, heat escapes and prolongs cooking time.

❌ Skipping the Stall Wrap

The stall can add hours to your cook if you don’t wrap.

❌ Cutting Too Soon

Letting it rest is just as important as cooking. Cutting early leads to dry pork.

Summary: Time Chart for a 10lb Boston Butt

Temp	Time Estimate	Notes
225°F	15–20 hours	Best for tender pulled pork
250°F	12–15 hours	Faster but still tender
275°F	10–12 hours	Watch for overcooking
Internal Temp Goal	195–205°F	Use a meat thermometer
Rest Time	1–2 hours	Do not skip this step

Final Thoughts

Grilling a 10lb Boston butt is a labor of love, but the reward is absolutely worth the wait. From the rich bark and smoky aroma to the juicy, melt-in-your-mouth texture, this cut shines when given time and attention. Whether you’re feeding a backyard crowd or meal-prepping for the week, a properly grilled Boston butt is the ultimate BBQ hero.

Stick to the low-and-slow method, monitor your temperatures closely, and don’t rush the rest. With this complete guide, you’ll have everything you need to transform that massive pork shoulder into a BBQ masterpiece.