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Smoked Pulled Pork Sandwich (Tender, Juicy & Full of Flavor)

This Smoked Pulled Pork Sandwich is a classic BBQ favorite made with slow-smoked pork shoulder that becomes incredibly tender and juicy. The pork is seasoned with a flavorful dry rub, smoked low and slow for several hours until it easily pulls apart. Pulled pork is sandwiched between a toasted brioche bun, layered with a fresh homemade coleslaw and your favorite barbeque sauce. It is a crowd-pleasing comfort food that's perfect for backyard barbeques, family gatherings, or a satisfying weekend meal.
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Prep Time 15 minutes
Cook Time 8 hours
Total Time 8 hours 15 minutes
Servings: 8 people
Course: Main Course
Cuisine: American
Calories: 548
Ingredients Equipment Method Notes

Ingredients
  

  • 4-6 lbs Pork shoulder/butt
  • 2 Tbsp Yellow mustard
  • 3 Tbsp Brown sugar
  • 2 Tbsp Smoked paprika
  • 2 Tbsp Garlic powder
  • 2 Tbsp Onion powder
  • 2 Tbsp Salt
  • 2 Tbsp Black pepper
  • 1 tsp Chilli powder
  • 1/2 tsp Cayenne powder (optional)
For spritzing (optional)
  • Apple juice or apple cider vinegar
For Serving:
  • Brioche buns toasted with butter
  • Coleslaw
  • Red pickled onions
  • BBQ sauce

Equipment

  • 1 Smoker

Method
 

  1. Prepare the Pork: Pat the pork shoulder dry with paper towels. Rub the entire surface lightly with mustard. This helps the seasoning stick and adds a subtle flavor.
  2. Season the Meat: Mix the brown sugar, paprika, garlic powder, onion powder, salt, pepper, chili powder, and cayenne. Generously coat the pork shoulder on all sides. Let the pork sit in room temperature for 30-45 minutes while the smoker heats up.
  3. Heat up the Smoker: Heat up the smoker by using charcoal250F (121C). Good wood choices include: Hickory, Applewood, Cherry, or Oak. I always use the apple woods chips with hardwood charcoal. Avoid over-smoking. Thin blue smoke is what you’re after, not thick white clouds. I use the Louisiana Egg smoker and it turns out every single time to perfection.
  4. Smoke the Pork: Place the pork shoulder directly on the smoker. Smoke for about 6-8 hours, or until the internal temperature reaches 165F (74C) Make sure the outside is nice and crusty and the fat is nicely rendered off. Optional: Spritz the pork with apple juice every hour to keep it moist.
  5. Wrap and Continue Cooking: Once the pork reaches 165F, wrap it tightly in aluminum foil. Return it to the smoker and cook until the internal temperature reaches 203F (95C) This usually takes 2-4 hours.
  6. Rest the Pork: Remove the pork from the smoker and let it rest for at least 45 minutes in a cooler. Keep the pull pork wrapped in aluminum foil. This step allows the juices to redistribute and makes the pork pull apart effortless.
  7. Shred the Meat: Using two forks, pull the pork apart. Mix the meat with its juices for maximum flavor.
  8. Assemble the Pulled Pork Sandwich: Toast the brioche buns with butter in a frying pan until nice and golden. Place pulled pork on the bottom bun and drizzle with BBQ sauce. Generously add coleslaw on top of the pork and red pickled onions. Enjoy!

Notes

Tips for Perfect Pulled Pork:
  • Choose the Right Cut: Pork shoulder (pork butt) has enough fat to stay juicy during the long cooking process. Don't be tempted to cut it off.
  • Don't Rush the Process: Pulled pork needs time to smoke. Cooking low and slow is the key to tender meat. The process takes pretty much a whole day but it's so worth it. You will never want to go back to crockpot pulled pork as that doesn't get the smoky flavor.
  • Cook to Temperature, Not Time: This recipe gives you a guideline of the estimate time it takes to smoke a pulled pork but the ideal internal temperature is 203F.
  • Let It Rest: Resting prevents the juices from escaping when shredding.