No-Wrap BBQ Pork Butt on a Pellet Grill: Perfect Pulled Pork Sandwiches Recipe

 #Pellet Grill #Pork #Pork Butt 

Unwrapping the secret to creating delicious and juicy pulled pork sandwiches, this no-wrap BBQ pork butt recipe is perfect for your next gathering. Smoking a pork butt without wrapping it in foil allows for a perfect bark formation while keeping the meat moist and tender. Wrapping a pork butt can speed up the cooking process and help retain moisture, but you may miss out on that irresistible bark. Unwrapped, you'll get a more pronounced smoke flavor and an exceptional crust. Let's dive into the process of smoking a pork butt to perfection.

1. Choosing the Perfect Pork Butt

When selecting a pork butt from the store, look for a well-marbled piece with a thick, even fat cap. The size depends on your needs, but a 6-10 pound bone-in pork butt is ideal for this recipe. A bone-in pork butt tends to have more flavor and moisture than a boneless one. Plus if you can pull the bone out, and there is no meat attached, your pork is perfect,y cooked.

2. Trimming the Fat

Trimming some of the fat from the pork butt allows the seasoning to penetrate the meat better and ensures even cooking. However, don't over-trim, as the fat contributes to the flavor and keeps the meat moist during the long cooking process.

3. Seasoning the Pork Butt

A pork butt can handle a generous amount of seasoning, as it's a large cut of meat cooked low and slow. Coat the pork butt with yellow mustard and then liberally apply your favorite BBQ rub. Let it sit for at least 15-30 minutes, but overnight is even better for maximum flavor.

4. Preparing Your Grill

Set your pellet grill to 200°F and engage the super smoke setting. If your grill doesn't have this feature, you can set it to 225°F. A wireless meat thermometer is recommended for monitoring the temperature without disturbing the cooking process.

5. Cooking the Pork Butt

Place the pork butt on a higher rack in the grill for optimal temperature control. The cooking time will vary depending on the size of the pork butt, but expect around 10 hours for a 6-10 pound piece, aiming for an internal temperature of 180°F.

6. Finishing It Off

If your pork butt's temperature stalls, you can bump the grill temperature up to 275°F to speed up the process. Cook for an additional couple of hours until the internal temperature reaches 195-200°F.

7. Resting the Pork Butt

Remove the pork butt from the smoker and let it rest for at least 30 minutes, allowing the juices to redistribute evenly throughout the meat.

8. Pulling the Pork

Using two forks or bear claws, shred the meat into bite-sized pieces, discarding any excess fat or bone.

9. Serving

Serve the pulled pork on buns with your favorite BBQ sauce and additional toppings as desired.


Smoking a pork butt without wrapping it on a pellet grill results in tender, juicy, and flavorful pulled pork, perfect for mouthwatering sandwiches. Follow these steps to achieve that heavenly bark and smoky flavor that will have your guests asking for seconds. Happy smoking!