Smoked Chuck Roast Chili is the ultimate cold-weather comfort food , bold, smoky, hearty, and deeply flavorful in every bite. The first time I made this chili, I couldn’t believe how much the smoker transformed a simple chuck roast into something incredibly rich and tender. The meat absorbs layers of smoke before it’s simmered with tomatoes, beans, peppers, and spices, resulting in a chili that tastes like it cooked in a Texas barbecue pit all day. It’s rustic, satisfying, and perfect for anyone who loves smoky flavors. You can serve it thick like a stew or a bit looser like classic chili, and no matter how you make it, this recipe always brings that irresistible slow-smoked aroma straight into your kitchen.
Why You’ll Love This Recipe
• Deep, authentic smoky flavor you can’t get from ground beef chili
• Chuck roast becomes incredibly tender after smoking and simmering
• One of the best chili recipes for fall, winter, game days, or potlucks
• Smoker + stovetop combo gives layered flavor without extra work
• Thick, hearty texture , the kind of chili that stands up on a spoon
• Customizable spice level and perfect for toppings
• Leftovers taste even better the next day
Ingredients
• 3–4 lb chuck roast, trimmed and cut into large chunks
• 2 tbsp olive oil
• 1 large onion, diced
• 1 jalapeño, seeded and diced (optional)
• 1 green pepper, diced
• 4 garlic cloves, minced
• 2 (15 oz) cans kidney beans, drained and rinsed
• 1 (15 oz) can black beans, drained and rinsed
• 1 (28 oz) can crushed tomatoes
• 1 (15 oz) can diced tomatoes
• 1 cup beef broth
• 2 tbsp tomato paste
• 3 tbsp chili powder
• 1 tbsp smoked paprika
• 2 tsp cumin
• 1 tsp oregano
• ½ tsp chipotle powder (optional for heat)
• 1 tsp salt
• ½ tsp black pepper
Preparation Steps
STEP 1: SEASON THE MEAT
• Pat the chuck roast dry and cut into large chunks.
• Rub with salt, pepper, chili powder, and smoked paprika.
STEP 2: SMOKE THE CHUCK ROAST
• Preheat smoker to 225°F.
• Place meat directly on smoker grates and smoke for 2–3 hours until browned and smoky.
• Remove, let rest 10 minutes, then cut into bite-size cubes.
STEP 3: BUILD THE CHILI BASE
• Heat olive oil in a large pot.
• Add onion, jalapeño, garlic, and green pepper; sauté 4 minutes.
• Stir in tomato paste, chili powder, cumin, oregano, smoked paprika, and chipotle powder; cook 1 minute to bloom spices.
STEP 4: ADD TOMATOES & BEANS
• Add crushed tomatoes, diced tomatoes, beans, and beef broth.
• Stir well.
STEP 5: ADD THE SMOKED BEEF
• Add the smoked chuck roast pieces into the pot.
• Bring chili to a simmer.
STEP 6: SLOW SIMMER
• Cover and simmer on low for 1.5–2 hours, stirring occasionally, until beef is tender and chili thickens.
STEP 7: TASTE & SERVE
• Adjust seasoning as needed.
• Serve hot with cheese, sour cream, or tortilla chips.
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Cooking Notes
• Chuck roast gives the best texture , ground beef won’t compare
• Smoky flavor intensifies as chili simmers
• If too thick, add broth; if too thin, simmer uncovered
• Let chili rest 10 minutes before serving
• Smoking longer gives stronger barbecue flavor
Variations
• Add corn for sweetness
• Add diced potatoes for a hearty stew-style chili
• Swap kidney beans for pinto beans
• Add bourbon or dark beer for depth
• Make extra smoky with liquid smoke
• Add adobo peppers for spicy heat
Serving Suggestions
• Serve with cornbread or crusty bread
• Top with cheddar, sour cream, green onions, or avocado
• Serve over mashed potatoes or rice
• Scoop with tortilla chips
• Add pickled jalapeños for tang
Tips
• Smoke meat the day before for easy next-day cooking
• Cut meat into large chunks so it doesn’t dry out in smoker
• Use wood like hickory or mesquite for deeper smoke
• Stir chili occasionally to prevent sticking
• Freeze leftovers flat for quick future meals
Prep Time / Cooking Time / Total Time
• Prep Time: 20 minutes
• Cooking Time: 4 hours
• Total Time: 4 hours 20 minutes
Nutritional Information (Per Serving, approx.)
450 calories – 42g protein – 19g fat – 28g carbs
FAQs
Do I have to smoke the chuck roast?
- Smoking creates the signature flavor, but if you skip it, sear the meat very well in a hot skillet to build that smoky depth.
Can I cook this in a slow cooker after smoking the meat?
- Yes. After smoking, transfer everything to the slow cooker and cook on LOW for 6–7 hours or HIGH for 3–4 hours.
What wood chips work best?
- Hickory, mesquite, oak, and pecan give the richest flavor. Fruit woods like apple are milder.
Can I make this chili spicy?
- Add jalapeños, chipotle peppers, cayenne, or hot chili powder to build heat.
Does smoked chili freeze well?
- Yes. It freezes beautifully and tastes even better after reheating because the flavors deepen over time.
Conclusion
Smoked Chuck Roast Chili is one of the most flavorful chili recipes you can make , deeply smoky, rich, thick, and packed with tender beef. By smoking the chuck roast first and then simmering it with tomatoes, beans, peppers, and spices, you create a bowl of chili that feels like a true barbecue-style comfort dish. Whether you’re cooking for game day, a cozy weekend, or meal prep, this chili always delivers hearty flavor and unbelievable texture. It’s the kind of recipe that keeps people coming back for seconds every time.
