Bobby's Smoked Chuck Roast

Prepare your smoker: Preheat your smoker to a consistent 275°F (135°C), following the manufacturer's instructions for optimal smoking. (Prep time: 15 minutes)

Prepare the Roast: In a small bowl, thoroughly combine the kosher salt, black pepper, granulated garlic, and Montreal steak seasoning. Generously rub this mixture all over the chuck roast, ensuring an even coating. Place the seasoned roast in a sturdy baking pan. (Prep time: 5 minutes)

Initial Smoke: Place the prepared baking pan with the roast into the preheated smoker. Smoke the roast until an instant-read thermometer inserted into the thickest part registers 165°F (74°C). This will typically take approximately 4 to 4 ½ hours, depending on your smoker and the size of the roast. (Cook time: 4 to 4.5 hours)

The Texas Crutch: Remove the baking pan from the smoker. Wrap the roast tightly in a double layer of heavy-duty aluminum foil. Return the wrapped roast to the smoker and continue smoking until the internal temperature reaches 195°F (90°C), about 1 hour more. (Cook time: 1 hour)

Rest and Render: Transfer the wrapped roast to a cutting board. Allow it to rest, still wrapped, for at least 20 minutes. This allows the juices to redistribute, resulting in a more tender and flavorful final product. Leave the smoker on during this resting period. (Rest time: 20 minutes)

Burnt Ends Transformation: Carefully unwrap the roast, reserving any accumulated juices. Cut the roast into roughly 1-inch cubes. Return the cubed roast to the baking dish. (Prep time: 10 minutes)

Sweet and Smoky Glaze: In a bowl, combine the barbecue sauce and dark brown sugar. Pour this mixture over the cubed roast in the baking dish, stirring gently to ensure all the cubes are evenly coated. (Prep time: 5 minutes)

Final Smoke for Burnt Ends: Return the baking dish to the smoker. Smoke the cubed roast for an additional 1 ½ to 2 hours, or until the sauce has caramelized and the burnt ends have reached your desired level of stickiness and char. Stir occasionally to prevent sticking and promote even caramelization. (Cook time: 1.5 - 2 hours)

Serve: Remove from the smoker and serve immediately. The smoked chuck roast burnt ends are delicious on their own, as sliders, or as a topping for baked potatoes.