Pulled pork is a backyard BBQ staple, and this is the method I rely on when I want results I don’t have to babysit. By combining smoking and sous vide, you get the best of both worlds: real smoke flavor and reliably tender, juicy pork—every single time. This approach is especially great for entertaining. Most of the work happens well before guests arrive, and the final result is pork that pulls apart effortlessly and holds beautifully for serving. It’s a bit of a time investment, but very little of it requires your attention.
First Smoke (3 hours at 225°F)
This step develops the pork’s foundational flavor and appearance. Smoking at a low temperature allows a beautiful smoke ring to form and gives the meat its deep, savory bark. It won’t cook the pork all the way through—but it sets the stage with that unmistakable BBQ aroma and color.
Sous Vide (165°F for 20 hours)
After the initial smoke, the pork is vacuum-sealed and cooked low and slow in a precisely controlled water bath. At 165°F, the collagen in the pork shoulder gradually breaks down, transforming tough connective tissue into melt-in-your-mouth richness while locking in moisture. This step is what guarantees fork-tender pulled pork every time.
I use an Anova Sous Vide
Final Smoke (2 hours at 275°F)
Once the pork is tender and rested, it goes back on the smoker to finish. This high-heat smoke firms up the outside, revives the bark, and layers on even more smoky depth. It also helps reduce any surface moisture from the sous vide step, giving you that perfect bite: crispy on the outside, tender inside.
BBQ Pulled Pork Serving Ideas
- Classic BBQ pulled pork sandwiches with pickles and slaw
- Tacos with lime crema and fresh jalapeños
- Nachos with melted cheese, beans, and green onions
- Add to mac and cheese or baked potatoes for an indulgent twist
BBQ Pulled Pork
Equipment
- Smoker
- Sous vide machine + large container
- Vacuum sealer or heavy-duty bags
- Meat thermometer
- Towels for resting
Ingredients
- 1 bone-in pork butt (pork shoulder) 6–8 lbs
- ½ cup Yellow mustard
- 1 cup BBQ dry rub
- applewood or hickory wood chunks for smoking
Instructions
Day Before ( Start 10:00 AM if Lunch Tomorrow)
- Start by trimming any large pieces of excess fat, but leave enough to keep it juicy during the cook. Rub the pork butt with yellow mustard to help the spice rub stick, then coat it generously with your BBQ dry rub, making sure to cover all sides.
- Preheat your smoker to 225°F and place the pork butt directly on the grates. Smoke for 3-4 hours, or until the bark starts to set and you see a nice smoke ring developing. This step adds rich, smoky flavor and color.
- Once smoked, let the pork rest for 30 minutes to cool slightly. Then vacuum seal it and place it in a sous vide bath at 165°F for 20 hours. This long, slow cook breaks down all the connective tissue and results in melt-in-your-mouth pork.
Day Of (Start 9:00 AM for Lunch)
- After the sous vide bath, let the pork rest for at least 1 hour—this step helps it firm up slightly and reabsorb some liquid before going back on the smoker. Preheat your smoker to 275°F and return the pork to the grates for a final 2-hour smoke. This firms up the bark and reintroduces more smoky flavor.
- Once it’s off the smoker, use two forks to shred the pork. It should fall apart easily with just a little pull. Pile it high on buns with slaw, serve it plate-style with sides, or toss it in your favorite BBQ sauce.
