How to Make Smoked Chuck Roast

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Have you ever had smoked chuck roast?

Our daughter is back in school, and the morning temperatures are creeping into the high 40s. In just a few more weeks the leaves will start to turn color, and Fall will be here! I love the Fall and everything that comes with it. More football, great weather, and the first signs of comfort food creeping its way onto our table. One of those comfort foods that I just love to make, is smoked chuck roast.

This smoked chuck roast recipe with roasted butternut squash is perfect for the Fall. If you're looking for a great pellet smoker recipe for the Fall, look no further! 

Right now, Albertson's on Broadway and Albertson's Market Street have everything you need to make the perfect Fall feast. Be sure to check them out!

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Why I Love Smoked Chuck Roast

I love making smoked chuck roast. It’s always affordable, and there are so many great ways you can use it. It’s great in smoked chili, on a bun, or in tacos too!

One of my favorite ways to use chuck roast is by slicing it thin after a long session on my smoker. Serve it next to some smoke-roasted butternut squash, and you have a meal that is perfect for Fall.

sliced chuck roast on a cutting board

Other Ingredients You’ll Need for Smoked Chuck Roast

In addition to the chuck roast, you’ll also need the following ingredients:

  • Salt
  • Pepper
  • Yellow Mustard
  • Garlic Powder
  • Onion Powder
  • Butternut Squash
  • Brown Sugar

Simple, right?!

Prepping the Chuck Roast

When you’re ready to get started, get out a cast-iron skillet just large enough to hold your chuck roast. Apply a thin layer of yellow mustard to the surface of the chuck roast, and then apply your bbq rub – recipe below – to all sides of the chuck roast.

chuck roast in a cast iron skillet
seasoned chuck roast in a cast iron skillet

Smoking a Chuck Roast

Set up your smoker to smoke at 275 degrees using indirect heat. When the smoker is up to temp place the cast-iron skillet in the smoker. Let the chuck roast smoke for about two hours, and then flip in the skillet.

chuck roast in a cast iron skillet

I like using a cast-iron skillet to smoke chuck roast because it allows the meat to cook in its own juices. I flip after two hours to help develop a bark on all sides of the meat.

When the internal temperature of the chuck roast hits 160 degrees cover the skillet tightly with foil. Continue cooking until the internal temp hits 200 degrees, approximately 4-5 hours of total cook time.

When the chuck roast gets to temp remove it from the smoker and place in a cooler to let it rest for about an hour.

After an hour remove the cast-iron skillet from the cooler and remove the chuck roast. Slice it thin against the most prominent grain of the meat.

sliced smoked chuck roast

Roasted Butternut Squash

While the smoked chuck roast is resting in the cooler, you can cook the butternut squash. It’s easy to do! Remove the skin from the squash using a vegetable peeler. Once all of the skin is removed cut the squash in half.

Scoop out the seeds and stringy mess from the inside of the squash, and then cut it into cubes. I shoot for 1×1 cubes here but the size is up to you. Toss the cubes in some olive oil, and then sprinkle with salt, pepper, and brown sugar.

Place the cubes on a lined baking sheet and cook in the smoker at 375 degrees for about 30-45 minutes.

smoked chuck roast with butternut squash

A Delicious Meal – Smoked Chuck Roast and Roasted Butternut Squash

This is such an easy meal to put together, and the beefy flavor of the chuck roast compliments the butternut squash perfectly. I hope you take the time to make this meal, it’s definitely worth it.

Love this recipe? Check out my fool-proof smoked brisket recipe!

slices of smoked chuck roast with butternut squash and brussel sprouts

Smoked Chuck Roast and Butternut Squash

Prep Time: 15 minutes
Cook Time: 5 hours
Additional Time: 1 hour
Total Time: 6 hours 15 minutes

Welcome the flavors of fall with this beefy smoked chuck roast and butternut squash recipe. It's easy to make, and healthy too!


  • 4-5 pound Beef Chuck Roast
  • 1 Whole Butternut Squash
  • 1 tsp Salt
  • 1 tsp Black Pepper
  • 1 tsp  Brown Sugar
  • 1 Tbsp Yellow Mustard

Chuck Roast Rub

  • 1 Tbsp Kosher Salt
  • 1 Tbsp Black Pepper
  • 1 tsp Garlic Powder
  • 1 tsp espresso Ground Coffee


  1. Apply a thin coat of yellow mustard to the surface of the chuck roast.
  2. Coat the chuck roast with bbq rub. Place the chuck roast in a cast-iron skillet.
  3. Set up your smoker to smoke at 275 degrees using indirect heat.
  4. Smoke the chuck roast for 2 hours, and then flip in the cast iron skillet.
  5. Continue cooking until the internal temperature hits 160 degrees, and then cover tightly with foil. When the internal temperature hits 200 degrees remove the cast iron skillet from the smoker and place in a large cooler to rest.
  6. While the chuck roast is resting peel the butternut squash, scoop out the seeds, and cube it.
  7. Coat in olive oil and toss in salt, pepper, and brown sugar.
  8. Arrange the cubes on a lined baking sheet and cook in your smoker at 375 degrees for 25 minutes.

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Nutrition Information:



Serving Size:


Amount Per Serving: Calories: 687Total Fat: 43gSaturated Fat: 18gTrans Fat: 3gUnsaturated Fat: 23gCholesterol: 235mgSodium: 1402mgCarbohydrates: 4gFiber: 1gSugar: 1gProtein: 70g

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6 Replies to “How to Make Smoked Chuck Roast

  1. Can you taste the mustard? My husband doesn’t like mustard. Do I need to use it or is there something else I can use. Thanks

    1. You can’t really taste the mustard, it just adds to the overall flavor. But if you don’t want to use it you don’t have to.

  2. Unfortunately I do not own a cast iron skillet what can I use instead? Your recipes taste great by the way keep the coming thanks Sandy

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