In my quest to level up the classic Smoked Pulled Pork Sandwich, I’ve infused this great recipe with some creative additions that add even more excitement to an already epic classic.

What could elevate smoked pulled pork beyond its already near-perfect culinary status? How about chorizo sausage, melted pepper jack cheese, crispy onion rings, tangy BBQ sauce, and some crunchy coleslaw… Need I say more?

This is an epic Smoked Pulled Pork Sandwich, elevated with chorizo sausage, onion rings, pepper jack, bbq sauce, and coleslaw.

It never ceases to amaze me how a combination of simple ingredients on hamburger buns can taste so freakin’ delicious.

Why You’ll Love Smoked Pulled Pork Sandwich

What’s not to love about a good pulled pork sandwich? Tender shreds of perfectly smoked pork get infused with the rich, smoky essence that only slow cooking can achieve.

With so many different ways to make a delicious pulled pork sandwich, my idea of perfection is laid out in the recipe card below. So, if your interest and appetite are piqued, then keep on scrolling! 

A close up of the shredded smoked pork.

If this is your first time smoking some pork butt, you’re gonna be blown away by the results. The slow cooking process is the best cooking method to achieve maximum flavor and tenderness.

With each tender bite of pork, you’ll know that the long cook time was worth all the effort. The next time you’re craving a little taste of the southern United States, then this recipe should do the job.

If you love BBQ pork sandwich recipes, check out these recipes too: Pulled Pork BBQ Sandwich, Chipotle BBQ Pulled Pork Sandwich Recipe, and Al Pastor Pulled Pork Sandwich.

Pork Sandwich Recipe Ingredients 

  • Pork – For this easy pulled pork recipe, a whole bone-in pork butt (aka Boston Pork Butt) is first slathered in yellow mustard. The mustard lays the groundwork for the dry rub. For this recipe, I’ll be using Maple Bourbon Rub, my go-to pork rub. 

To find my Maple Bourbon Rub, or any of my other spices, check them out by clicking in the below box that will lead you to my collaboration page with Spiceology.

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  • Crutch – Ask any BBQ Pit Master the best way to achieve tender meat and I’ll bet they’ll mention the crutch. It’s the savory, fatty, and often boozy liquid that keeps the pork from drying out. In this recipe, the beer and beef broth crutch gets some extra heat and flavor from smoked chorizo. The sausages then make the perfect accompaniment to the finished sandwiches. 
  • Bread – Remember, the higher the quality of hamburger buns, the better the sandwich holds up with all those weighty ingredients inside. 
  • Fixins‘ – Sliced pepper jack cheese, fried onion rings, favorite barbecue sauce, and coleslaw (optional) finish off this sandwich masterpiece. For the onion rings, just buy your favorite premade from the grocery store, so you don’t have to fuss with them too much. If you’re not feeling jack cheese, Swiss cheese or cheddar cheese are other solid options.

Okay, my friends, I hope by now that I have convinced you that the Smoked Pulled Pork Sandwich is a delicious recipe that you gotta make.

How to Make the Best Pulled Pork Sandwiches 

Pork Prep

Prepping the pork butt for the Smoked Pulled Pork Sandwiches.

First, let’s lay the pork butt on a baking sheet. Cover every side with some yellow mustard and a generous sprinkling of Maple Bourbon Rub. Place pork in the fridge, uncovered, for at least 4 hours. If you’ve got the time, let it rest overnight.

Smoker Time

Now, let’s get that smoker doing what it does best, smoking. Preheat it to around 250° degrees F. If you’re craving extra smoky flavor, then toss in some wood chips or chunks.

The Pork Butt on the smoker grill grates before and after 3 hours of cooking.

Take the seasoned pork butt out of the fridge and then lay it on the grill. It will stay there covered until the meat hits an internal temperature of 165° degrees F. The cooking time for this step is about 4-6 hours.

Crutch Time

Once the pork butt has reached the right internal temperature, transfer it to a large aluminum foil bin. Now, this is where the crutch steps in to keep the meat from drying out. Pour in some beef broth and light beer until it hits about halfway up the pork butt.

Seal up that bin tight with foil and get it back on the smoker at 250° degrees F. Let it smoke for another 3-4 hours until the meat is tender and ready to shred.

The pork and chorizo finishing up on the smoker and then pulling the pork to prepare it for serving.

While your butt is in the final stretch, throw in some chorizo sausage to join the crutch liquid until it hits 165° degrees F. Once everything is cooked to perfection, remove everything from the smoker and then let it all rest for a good 30 minutes.

Smoked Pulled Pork SAndwich Assembly

Now, it’s showtime for the ultimate Smoked Pulled Pork Sandwich!

Remove the bone from the pork butt and then give it a good shredding with your hands in some kitchen gloves. Pile that glorious shredded pork onto a burger bun with cheese, sliced sausage, BBQ sauce, onion rings, and coleslaw.

The pork is shredded, the chorizo sausage is sliced.

Serve it up and brace yourself for pure satisfaction!

What to Serve with the Smoked Pulled Pork Sandwich

A great way to enjoy the Smoked Pulled Pork Sandwiches is with more of your favorites. If you want to deviate from French fries, sweet potato fries are always a good idea. And, don’t forget the dill pickles! Always a winner with any BBQ pork sandwich.

The final sandwich is assembled and ready to eat.

Leftovers & Reheating

If you have any pulled pork or sausages left over, then wrap them in aluminum foil and keep them in an airtight container in the fridge for 3-5 days. You can reheat it by placing the pork in a foil bin on the grill with some beer and beef broth liquid. Layer between fresh hamburger buns and enjoy! 

More BBQ Sandwiches


Are bone-in pork shoulder and pork butt different things?

Yes, bone-in pork shoulder and pork butt are different cuts, although they both come from the shoulder region of the pig. The pork butt, also known as Boston Butt, is the upper part and is prized for its tenderness.

Can I prepare the smoked pulled pork sandwich recipe in advance and reheat it later?

Yes, you can prepare the pulled pork ahead of time. After smoking, refrigerate the shredded pork meat and chorizo sausages. Gently reheat it when ready and proceed with the other must-have accompaniments. 

What is the best wood to use in the smoker for pulled pork sandwiches?

The best wood for making the best smoked pulled pork sandwich depends. Fruitwoods like apple and cherry are great because they offer a mild, fruity sweetness. Hickory wood chips provide a classic and robust flavor, while pecan and maple add a sweet and nutty profile. In other words, it’s an art with no right or wrong answer.

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The epic Smoked Pulled Pork Sandwich.

Smoked Pulled Pork Sandwich

In my quest to level up the Smoked Pulled Pork Sandwich, I've infused this great recipe with some creative additions that add even more excitement to an already epic classic.
Author:Derek Wolf
5 from 1 vote
Prep Time: 1 hour
Cook Time: 8 hours
Total Time: 9 hours
Course: Dinner, Lunch
Cuisine: American
Servings: 10 people



  • 1 Whole Pork Butt bone in
  • 1 cup Maple Bourbon Rub
  • Yellow Mustard for binder


  • 36 oz Favorite Light Beer
  • 3-4 cups Beef Broth
  • ½ cup Pork Fat
  • 2-3 Smoked Chorizo Sausage


  • Burger Buns
  • Sliced Pepper Jack Cheese
  • Fried Onion Rings
  • Favorite BBQ Sauce
  • Coleslaw if desired


  • Place your pork butt on a baking sheet, lather with yellow mustard all over and generously season all sides with my Maple Bourbon Rub in order to completely cover the roast.
  • Place them in the fridge, uncovered, for at least 4 hours but ideally overnight.
  • Preheat your smoker to about 250 degrees F. Add some wood chips or wood chunks if desired for extra smoky flavor.
  • Pull your pork butt out and place it on the smoker to cook until it reaches an internal temperature of 165 degrees F (about 4-6 hours).
  • Once the pork butt has hit the temperature, pull it out and place it in a large foil bin.
  • Fill into the bin your beef broth and light beer. The liquid in the bin should come past 50% of the pork butt’s height, so add more or less if necessary.
  • Tightly cover your bin with foil and place it back on the smoker at 250 degrees F to smoke until the meat is tender to probe and shreddable (another 3-4 hours).
  • As the butt cooks for the final 3 hours, add your chorizo sausage to cook until 165 degrees F.
  • Once the pork butt & sausage are done, pull them off and let them rest for 30 minutes.
  • Remove the bone and shred the pork. Slice the sausages.
  • Add the shredded pork to a burger bun with pepper jack cheese, sliced smoked sausage, BBQ sauce, and onion rings. Serve and enjoy!



Serving: 8Oz | Calories: 304kcal | Carbohydrates: 19g | Protein: 14g | Fat: 17g | Saturated Fat: 7g | Polyunsaturated Fat: 2g | Monounsaturated Fat: 6g | Trans Fat: 0.02g | Cholesterol: 50mg | Sodium: 308mg | Potassium: 381mg | Fiber: 3g | Sugar: 1g | Vitamin A: 717IU | Vitamin C: 6mg | Calcium: 254mg | Iron: 9mg

Derek Wolf

Derek is the driving force behind Over the Fire Cooking. He started cooking with live fire in 2016 and decided to start a social media page so his friends and family could follow the journey. Fast forward to today and Over the Fire Cooking has spread across multiple platforms with millions now following Derek's fire cooking journey. He's a southern fellow who enjoys everything from classic BBQ to Central and South American inspired dishes. Whatever he's cooking up, it's guaranteed to be so freakin' delicious!

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