Chipotle BBQ Pulled Pork Sandwich Recipe

If it’s your first time smoking a Boston pork butt, don’t be intimidated by how much time it can take to achieve the ultimate pulled pork perfection! While the cooking process is lengthy, it is also very simple and straightforward. 

Plus, once you experience the meat’s tenderness after slow cooking on the smoker, you’ll wish you jumped on this bandwagon sooner! It always amazes me how one simple recipe with simple ingredients can deliver so much deep and complex flavor! 

Perfect for large gatherings and family dinners, chipotle BBQ pulled pork is one of those classic recipes – one of my favorite recipes to make any time of the year – that yields plenty of shredded pork for sandwiches and leftovers for your pulled pork tacos, burritos, or nachos. 

This recipe is also an excuse to make more of my easy homemade barbecue sauce with local honey, brown sugar, apple cider vinegar, and chipotle peppers. If you like the deep, smoky flavor of chipotle as much as I do in your cooking, check out Chipotle Beer Steak Tacos and Chipotle Garlic Chile Con Carne.

Why You’ll Love This Pulled Pork Sandwich Recipe

The secret to this sandwich’s deeply satisfying flavor is Lone River Ranch Water, a refreshing and killer hard seltzer made with agave nectar and a splash of lime. It gives a touch of sweetness and acidity to the smoked pork in all the right measures. 

So what are you waiting for? Go ask your local butcher for the best boneless Boston butt and let your smoker deliver the best smoked pork ever!

Pulled Pork Sandwich Recipe Ingredients

The Main Stars:

• Pork Butt – Contrary to the name, this is not actually a pig’s butt, but the upper shoulder, where the best tasting fatty meat is found, perfect for slow-cooking in the smoker. 
• BBQ Seasoning – With no shortage of pork rubs and BBQ seasonings on the market, have fun experimenting until you find your personal favorite, or easily make your own with 2 tablespoons of paprika, 1 tablespoon each of salt, black or white pepper, paprika, chipotle powder, garlic powder, onion powder, and cumin, plus a teaspoon of cayenne to your desired level of heat. 
• Yellow Mustard – Never underestimate the depth of flavor a good yellow mustard can bring to all your favorite BBQ recipes. 

The Faithful Side Kicks:

• Burger Buns – You can get as basic as the cheapest hamburger buns, and the pulled pork sandwiches will still taste freaking amazing, or level up to the brioche buns that hold their shape better. 
• Lone River Ranch Water – This hard seltzer crafted with agave and lime is a match made in BBQ heaven! Not only does it make the perfect spritzer ingredient, it’s the perfect refreshing tequila-inspired beverage to go with the sandwiches! 
• Apple Cider Vinegar – Every cook should keep at least two giant bottles of versatile ACV in their pantry. In this recipe, it’s part of the spritz that helps tenderize and flavor the meat and a key ingredient in the BBQ sauce. 
• Beef Broth – Made from simmering beef bones and vegetables, this savory liquid helps steam the pork after it’s cooked low and slow for 6 hours.
• Ketchup – This classic condiment made from tomatoes, vinegar, and seasonings, adds a sweet and tangy element to the BBQ sauce.
• Local Honey – No homemade BBQ sauce would be quite as finger-licking good without the addition of a good honey. 
• Brown Sugar – This pantry staple adds the right amount of sweetness with hints of molasses to the barbecue sauce. 
• Chipotle Puree – Smoky and spicy chipotle peppers blended with vinegar and salt.

How to Make

Get ready to make the most delicious pulled pork sandwich recipe ever! Here’s how:

Place your pork butt on a baking sheet. Slather yellow mustard all over it, and generously season all sides with your favorite BBQ seasoning. Now, pop it in the fridge, uncovered, for at least 4 hours. If you can, let it sit overnight for the best results. 

Preheat your smoker to around 250F. Want that extra smoky kick? Add some hickory wood chips or chunks.

For more Pulled pork Recipes

Pulled Pork BBQ Nacho Table

Loaded Pulled Pork Quesadillas

Al Pastor Pulled Pork Sandwich

Pulled Pork Loin Nachos

Pulled Pork BBQ Sandwich

Pulled Pork Elote Tacos

Take the pork butt out of the fridge and put it on the smoker. Let it cook until it reaches an internal temperature of 165F (about 6 hours). To keep things nice and juicy, about every 20-30 minutes until that temp is reached, use a spritzer with Lone River Ranch Water and apple cider vinegar.

Once it’s reached 165F, pull the pork butt out and place it in a large aluminum foil bin. Pour in some beef broth and Ranch Water, enough to reach about halfway up the pork butt’s height. You can adjust the amount of liquid as needed. Now, seal up the bin tightly with foil and back onto the smoker at 250F for another 3-4 hours, or until the meat is tender and easily shreddable.

Now comes the hard part – let the pork butts rest for at least 30 minutes, but preferably an hour. Resist the temptation to dive in right away!

While the pork is resting is the perfect time to make the chipotle BBQ sauce. Heat up a cast iron skillet over medium-high heat (around 350F), and toss in all the sauce ingredients. Give it a good stir until it starts to simmer. Reduce the heat to medium (about 325F) and let it simmer for about 20 minutes or until the sauce thickens up. Once it’s done, take it off the heat and let it cool.

After the rest, it’s time to shred up that pork butt like a pro! Grab a toasted burger bun and load it up with a heap of shredded pulled pork! Then top is all with that lip-smacking Chipotle BBQ Sauce. Can you taste this pulled pork sandwich it already?

Then, grab a cold Ranch Water to wash it all down, and dig into the pulled pork sandwich of your dreams!

Love pulled pork? Try my Pulled Pork Loin Nachos, Al Pastor Pulled Pork Sandwich, Loaded Pulled Pork Quesadillas, or Pulled Pork BBQ Nacho Table!

How to Store Leftovers & Reheat

Store any leftover pork in an airtight container in the fridge for 3-4 days. When you’re ready to reheat, set the oven to 350F. Then heat on a baking pan for about 10-15 minutes, or heat in a large skillet over medium heat. 

What to Serve With a Pulled Pork Sandwich

When it comes to serving up a pulled pork sandwich, I like serving mine with baked beans. I like to add a touch of maple syrup to them in a cast iron skillet alongside the pork. Corn on the cob seasoned with your BBQ seasoning, grilled over the coals is another great side idea. 

Recipe FAQs

What’s the difference between boneless pork shoulder and pork butt?

Although both cuts are actually from the pig’s shoulder, the pork butt comes from the fattiest (i.e. tastiest) part of the shoulder.

Needing more spice in your life? My spice line can help with that. Check them out here.

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