Preheat the Smoker: Set your smoker for indirect grilling at 275°F. For the best flavor, use hickory or oak wood.
Season the Meat: Coat the chuck roast with yellow mustard, then generously season all sides with beef rub or a mix of salt, pepper, and garlic powder.
Smoke the Roast: Once the smoker is ready, place the seasoned chuck roast inside and close the lid. Smoke until the internal temperature reaches 165°F, which should take about 5 hours. At this point, the roast should have a dark, flavorful bark.
Wrap the Roast: Remove the roast from the smoker and wrap it tightly in butcher paper or aluminum foil. Return it to the smoker and continue cooking until the internal temperature reaches 195°F (about 1 hour).
Rest and Cut the Meat: Take the wrapped roast off the smoker and let it rest for 15-20 minutes. Then, cut the meat into ¾-inch cubes and place them in a foil baking pan.
Add Sauce and Brown Sugar: Sprinkle the cubes with ¼ cup of brown sugar and drizzle with most of your favorite BBQ sauce, saving a couple of tablespoons for later. Gently toss the meat to coat evenly.
Monitor Moisture: If the meat starts to look dry during smoking, lightly spritz it with apple juice or beef broth to keep it moist and enhance the flavor.
Check for Tenderness: Instead of relying solely on temperature, use a fork or toothpick to test the tenderness. The meat should be soft and easily pull apart when done.
Finish Smoking: Place the pan back on the smoker, close the lid, and cook for another 1.5 to 2 hours, or until the sauce is bubbly and the beef cubes are tender and caramelized.
Rest Before Serving: Allow the burnt ends to rest for at least 10 minutes after the final smoke. This helps the juices redistribute, making the meat even more flavorful and tender.
Serve and Enjoy: Add the remaining 2 tablespoons of brown sugar and the rest of the BBQ sauce. Stir gently and return to the smoker for a few more minutes. Serve hot as a main dish or on white bread/buns with pickles and sliced white onions.
