We’re sharing a step-by-step process on how to make smoked pulled pork using a Masterbuilt Gravity Series 800 Grill. We’re going to share insights on the process and tips for making your own smoked pulled pork sandwiches at home.

Smoked Pulled Pork Sandwiches

There’s got to be a good pulled pork sandwich somewhere in the line-up when it comes to summertime. But, to make a good pulled pork sandwich, you got to start with making good pork. For me, it all starts with firing up my Masterbuilt 800 Gravity Series. This multi-functional grill is also a smoker, which makes our Masterbuilt grill the MVP of summer.

If you love pulled pork sandwiches, check out these pulled bbq sandwiches:

Kansas City BBQ Pulled Chicken Sandwiches

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The Masterbuilt 800 Gravity Series also comes with a separate manifold to allow greater heat distribution for the griddle insert attachment. This is an all-around grill that gives you the ability to prepare just about cut of meat, from reverse searing steaks, making smoky tender ribs, juicy brisket, and of course pulled pork that literally falls apart after a long slow 190°F 12-hour smoking session. The heat is cranked up to 250°F until the pork butt reaches an internal temperature of 105°F.

I start with a boneless pork butt; you can also use a bone-in pork butt if that is your jam. I use the crosshatch technique to score the side of the pork butt with a layer of fat. Then I liberally rub a homemade, or store-bought rub, into the crevices of the pork fat. I also allow the completely thawed pork butt to come to room temperature before smoking. I am also fond of slicing two large onions, sweet or yellow onions will do, and placing them on the bottom of the large disposable aluminum high-walled pan. I place the pork butt on top of the sliced onions, insert the meat thermometer, then place the pan into the center of the preheated 190°F smoker.

As I mentioned earlier, I smoked the prepared pork butt for 12-hours at 190°F. After the 12-hour smoke is finished, I adjust the temperature to 250°F and barbecue the pork butt until the internal temperature reaches 205°F. I removed the finished pork butt from the Masterbuilt grill/smoker and allowed the meat to rest for fifteen minutes to allow the juices to redistribute.

It doesn’t take much to pull the pork apart; it literally falls apart. You will notice the surface of the meat has a pinkish hue; this means it has great smoke penetration and is incredibly tender.

I served our pulled pork sandwiches with coleslaw, chips, and pickles on a buttered and toasted brioche bun.

What You Will Need To Make Our Pulled Pork Sandwiches

Pork Butt. This cut of pork is also known as a Boston Butt or Pork Shoulder. I used a 10-pound boneless pork butt; a bone-in pork butt works well too. A 10-pound pork butt will yield a lot of meat, and it’s perfect for leftovers or freezing.

Onions. I used two large sweet or yellow onions sliced thinly. I use the onions to impart flavor and provide moisture; as the onions cook, they will release liquid, which helps keep the pork juicy.

Rub Seasoning. When it comes to adding a rub, use whatever kind of rub you like. Lately, I have been using an Umami mushroom-based rub mixed with a Mesquite rub, and the flavor is incredible. The combined rub mixture should be about 1/3 cup, enough to cover the top area of the pork butt completely.

How to make Smoked Pulled Pork

Ingredients:

10-pound Pork Butt
2 large onions cut into rings
1/3 cup seasoning rub
1 large aluminum pan

Directions:

Make sure the pork butt is at room temperature and even coat with the seasoning rub mixture.
Slice the onions and place them into the bottom of a large, high-walled aluminum pan. I used a 13 1/2″ x 9″ pan. Place the prepared seasoned pork butt into the pan on top of the onions.
Fill the hopper of the Masterbuilt 800 Gravity Series with your favorite lump charcoal and light. I used the Masterbuilt Lump Premium Hardwood Charcoal. Turn on the power, and plug the meat thermometer into one of four ports. Now, push the pointed end of the meat thermometer into the middle of the boneless pork butt. If you are smoking a bone-in pork butt, make sure the meat thermometer is inserted into the thickest part of the meat but not touching the bone. If the thermometer is touching the bone, it will give a false reading.
Turn on the Masterbuilt grill, adjust the temperature to 190°F, and set the timer for 12 hours.
Once the temp is at 190°F, place the pan containing the pork butt into the smoker and close the lid. During the 12-hour smoke, you will need to refill the hopper with additional lump charcoal one additional time.
After the 12-hour smoke, adjust the temperature to 250°F and continue to cook until you get an internal temperature of 105°F.
Remove the pork from the grill and allow it to rest for 15 minutes. Use two forks, or a meat shredder, to pull apart the pork. Add barbecue a little at a time until you get the desired amount.

Serve on toasted buns with coleslaw. Enjoy!

Do I have to add barbecue sauce to pulled pork?

Not at all. Serve the pulled pork with or without barbecue sauce; it’s totally up to you. I serve smoked pulled pork with the barbecue sauce on the side, so everyone has the option to add barbecue sauce or not.

What is the cut of meat used to make smoked pulled pork?

Typically, pork shoulder is the ideal cut of pork used to make pulled pork. It is a thicker cut of meat with a substantial fat cap. Most of the fat cap can be cut away; however, there is some debate as to whether to cut away fat or not. The thicker cut of the pork shoulder can also reduce the possibility of the meat drying out during the cooking process. I always trim away some of the fat cap but leave most of it intact. I also recommend a boneless pork shoulder because it is typically a little cheaper than a bone-in pork shoulder.

Should I cook the pork shoulder fat-cap up or fat-cap down?

I prefer cooking with the fat-cap up; this helps to baste the meat as the fat is rendered and it drips down into the meat; it adds flavor and helps to keep the meat tender!

Other ways to make pulled pork

Pulled pork can be made in the oven, is a slow cook, or my favorite way, in a smoker. Any of these methods can produce a tender and flavorful pulled pork.

Should I keep leftover pulled pork in the fridge?

Of course, but remember, pulled pork should only be kept in the fridge for 3-4 days at a temperature of at least 40°F or less. Frozen pulled pork can last up to 5-6 months in the freezer.

Suppose you don’t have a smoker; make sure to go online and check out masterbuilt.com to check all their incredible products. If you have any questions, make sure to drop us a line in the comments section down below. And if you make the recipe, please let us know.

*We received the Masterbuilt Gravity Series 800 Grill for a product review.

Find more pork recipes below:

Braised Smothered Pork + Black-Eyed Peas

savory Pork Soup

Mega-Stuffed Pork Quesadillas

Grilled Pork Chop + Black-Eyed Pea Soup