How to Cook a Boston Butt on a Gas Grill | Easy BBQ Guide

Ready to impress your guests with mouthwatering pulled pork? Look no further than your trusty gas grill and a Boston butt. This flavorful cut, despite its name, comes from the pork shoulder.

With our guide, you'll master the art of grilling this budget-friendly favorite, transforming it into tender, juicy perfection.

How to cook a Boston Butt on a Gas Grill?

Cook a Boston butt on a gas grill using indirect heat at 225-250°F. Apply a dry rub, place the meat fat-side up, and grill until it reaches an internal temperature of 195-205°F, about 1.5-2 hours per pound. Rest before pulling.

Key Takeaways:

• Choose a 4-8 pound Boston butt with good marbling.
• Set up a gas grill for indirect heat at 225-250°F.
• Apply a flavorful dry rub before grilling.
• Cook until internal temperature reaches 195-205°F.
• Let the meat rest for 30-60 minutes before pulling.
• Monitor temperature and use wood chips for a smoky flavor.

Selecting the Perfect Boston Butt

Size Matters

When choosing your Boston butt, aim for a cut between 4 to 8 pounds. This range is ideal for most grills and feeds a good-sized crowd. Remember, larger cuts will take longer to cook, so plan accordingly.

Quality Indicators

Look for meat with a rich, pink color and some marbling throughout. Avoid cuts with excessive fat caps or dark spots. A little fat is good for flavor, but too much can lead to flare-ups on your grill.

Bone-in vs. Boneless

Both options have their merits. Bone-in cuts often have more flavor and can be easier to handle on the grill. Boneless cuts cook a bit faster and are easier to slice.

If you're new to grilling, start with bone-in – it's more forgiving and helps maintain moisture during the long cooking process.

Fresh vs. Frozen

For your pork butt recipe, fresh is best. If using a frozen pork shoulder roast, thaw completely in the fridge before grilling. This ensures your pork recipe cooks evenly and absorbs seasonings better.

As you grill and let the roast cook, check the grill temp regularly. When it's time to remove from the grill, a properly prepared pork shoulder roast will yield the best results.

Preparing Your Gas Grill

Setting Up for Indirect Heat

The key to perfect Boston butt is indirect heat. Turn on one side of your grill, leaving the other side off. This creates a hot zone for searing and a cooler zone for slow cooking. For larger grills, light the outer burners and leave the center off.

Temperature Control Tips

Aim to maintain a steady temperature between 225°F and 250°F. Use a grill thermometer for accuracy. Don't rely solely on your grill's built-in thermometer – place an oven thermometer at grate level for the most accurate reading.

Using Wood Chips for Flavor

Want that authentic smoky flavor? Soak wood chips in water for 30 minutes, then wrap them in foil. Poke holes in the foil and place the packet on the hot side of the grill. Replace as needed throughout cooking.

Preheating and Cleaning

Preheat your grill for 15-20 minutes before cooking. While it's heating, give the grates a good scrub with a wire brush. Clean grates prevent sticking and ensure those perfect grill marks.

Preparing the Boston Butt

Trimming Excess Fat

Start by trimming the fat cap to about 1/4 inch thickness. This thin layer helps baste the meat during cooking without causing flare-ups. Use a sharp knife and work carefully to avoid removing too much.

Creating a Flavorful Dry Rub

A good dry rub is crucial for that perfect bark. Mix brown sugar, paprika, garlic powder, onion powder, salt, and black pepper as a base. Add cayenne for heat or dried herbs like thyme for extra flavor. Experiment to find your perfect blend.

Applying the Rub

Pat the Boston butt dry with paper towels. This helps the rub stick better. Generously coat all sides of the meat with your rub, massaging it in. Don't be shy – really work it into every nook and cranny.

Letting It Rest

After applying the rub, let the meat sit at room temperature for about 30 minutes. This allows the rub to penetrate the meat and helps it cook more evenly.

If you have time, you can even wrap it and let it sit in the fridge overnight for deeper flavor.

Optional Injection

For extra juiciness, consider injecting the meat. Mix apple juice, vinegar, and your rub for a simple injection. Use a meat injector to distribute the mixture throughout the Boston butt.

This step isn't necessary but can add incredible flavor and moisture.

The Grilling Process

Preheating the Grill

Start by preheating your gas grill to 225-250°F. This low-and-slow approach is key for tender, juicy pulled pork. Remember, you're aiming for indirect heat, so only light one side of the grill.

Give it about 15-20 minutes to reach a stable temperature.

Placing the Meat on the Grill

Once your grill is ready, it's showtime for your Boston butt. Place it fat side up on the cooler side of the grill. This positioning allows the fat to render down through the meat, keeping it moist. Close the lid and let the magic begin.

Maintaining Consistent Temperature

Consistency is crucial when grilling a Boston butt. Keep that lid closed! Every time you open it, you're losing heat and extending cooking time. Resist the urge to peek too often - once an hour is plenty.

Monitoring Internal Temperature

Your best friend during this process is a good meat thermometer. Insert it into the thickest part of the meat, avoiding bone or fat. You're aiming for an internal temperature of 195-205°F for that perfect pull-apart texture.

Handling the "Stall"

Don't panic when the internal temperature seems to stop rising around 150-170°F. This is normal and called "the stall." It happens as moisture evaporates from the meat's surface, cooling it. Be patient - it can last several hours.

Flipping and Rotating

While not strictly necessary, some grillers like to flip and rotate their Boston butt every couple of hours. This can promote even cooking, especially if your grill has hot spots. Use tongs or heavy-duty gloves to avoid piercing the meat.

Adding More Flavor

As the meat cooks, you can enhance its flavor. Spritz it with apple juice or cider vinegar every hour or so after the first few hours. This adds flavor and helps create that coveted bark.

Wrapping (Optional)

If the stall is taking too long, or you want to speed up cooking, consider the "Texas crutch." Once the meat hits about 165°F, wrap it tightly in foil or butcher paper. This traps moisture and can push through the stall faster.

The Home Stretch

As you approach the target temperature, start checking more frequently. The last few degrees can happen quickly. Once you hit 195-205°F, it's time to take it off the grill.

Resting Period

Resist the urge to dive in immediately! Let your Boston butt rest for at least 30 minutes, preferably an hour. This allows juices to be redistributed, ensuring every bite is moist and flavorful.

Wrap it in foil and a towel, then place it in a cooler for the best results.

Remember, grilling a Boston butt is a labor of love. It can take anywhere from 1.5 to 2 hours per pound, so patience is key. But trust us, when you're serving up that tender, flavorful pulled pork, it'll all be worth it!

Wrapping Technique

When to Wrap

Consider wrapping your Boston butt when it hits the stall, typically around 150-170°F. This technique, known as the "Texas Crutch," can help push through this plateau faster.

However, some pitmasters prefer to wrap later, around 170-180°F, to develop a crustier bark.

Materials to Use

You have two main options: aluminum foil or butcher paper. Foil creates a tighter seal, speeding up the cook but potentially softening the bark.

Butcher paper allows more breathability, maintaining some crispiness while still boosting the cooking process.

Benefits of Wrapping

Wrapping serves multiple purposes. It helps retain moisture, potentially reducing overall cook time.

It also gives you an opportunity to add extra flavoring. Consider adding a splash of apple juice or a pat of butter before sealing.

Wrapping Process

To wrap, remove the Boston butt from the grill and place it on your chosen material. If using foil, create a boat-like shape to catch juices. Wrap tightly, ensuring no steam can escape.

Return the wrapped meat to the grill and continue cooking until it reaches your desired internal temperature.

Finishing and Resting

Determining Doneness

Your Boston butt is ready when it hits an internal temperature of 195-205°F. At this point, the connective tissues have broken down, resulting in that melt-in-your-mouth texture we're after.

Use a reliable meat thermometer to check multiple spots, avoiding bone or fat pockets.

Proper Resting Techniques

Once you've reached the target temperature, it's time to rest. This crucial step allows juices to be redistributed throughout the meat.

Remove the Boston butt from the grill and wrap it tightly in foil if it isn't already.

Creating a Resting Environment

For optimal results, place the wrapped meat in a cooler lined with towels. This makeshift faux cambro maintains temperature while allowing the meat to rest. If you don't have a cooler, a turned-off oven works well too.

Resting Duration

Allow your Boston butt to rest for at least 30 minutes, but ideally up to 2 hours. This patience pays off in juiciness and tenderness. Don't worry about it getting cold – properly wrapped, it'll stay warm for hours.

Pulling and Serving

How to Pull the Pork

After resting, it's time to shred. Use two forks or meat claws to pull the pork apart. It should separate easily if cooked properly. Remove any large chunks of fat or gristle as you go.

For a mix of textures, leave some larger pieces alongside the finely shredded meat.

Mixing in Juices

Don't discard those flavorful juices! Pour them back over the pulled pork for extra moisture and flavor. Toss gently to distribute evenly.

Serving Suggestions

Serve your pulled pork on soft buns for classic sandwiches. Or get creative - try it on nachos, in tacos, or atop a salad. Offer barbecue sauce on the side, allowing guests to adjust to their taste.

Don't forget classic sides like coleslaw, baked beans, or cornbread to complete your BBQ feast.

Troubleshooting Common Issues

Dealing with Flare-Ups

Occasional flare-ups are normal, but persistent ones can char your meat. If this happens, move the Boston butt to a cooler part of the grill. Consider trimming excess fat before cooking to prevent this issue.

Keep a spray bottle of water handy to quickly douse any flames.

Addressing Uneven Cooking

If you notice uneven cooking, your grill may have hot spots. Rotate the meat every few hours to ensure all sides cook equally. Using a heat deflector or a pan of water can help distribute heat more evenly.

Managing Cooking Time Variations

Every piece of meat is different, so don't panic if yours is cooking faster or slower than expected. Focus on internal temperature rather than time. If it's cooking too quickly, lower the grill temperature.

If it's taking too long, you can increase the heat slightly or consider wrapping to speed things up.

Combating Dry Meat

If your pork is turning out dry, you might be overcooking it. Make sure you're not exceeding 205°F internal temperature. Also, try spritzing the meat with apple juice or vinegar during cooking to add moisture.

Tips for Enhancing Flavor

Basting Techniques

Elevate your Boston butt's flavor with strategic basting. Create a mop sauce using apple cider vinegar, your favorite BBQ sauce, and a dash of your dry rub.

Apply this mixture every hour after the first few hours of cooking. Use a silicone brush or mop to avoid disturbing the developing bark.

Experimenting with Wood Chips

Infuse smoky goodness into your pork by adding wood chips to your gas grill. Soak hickory, apple, or cherry wood chips in water, then place them in a smoker box or foil packet.

Position this over the lit burner for continuous smoke flavor throughout the cook.

If you are interested in getting a smoker, consider our drum smokers which might help you for outdoor cooking.

Customizing Your Rub

Don't be afraid to get creative with your dry rub. Start with a basic blend of salt, pepper, and paprika, then add your personal touch.

Try brown sugar for sweetness, cayenne for heat, or ground coffee for depth. Remember to apply the rub generously for maximum flavor impact.

Injecting for Juiciness

For an extra flavor boost, try injecting your Boston butt before grilling. Mix apple juice, your rub, and a bit of vinegar for a simple injection that adds moisture and taste throughout the meat.

Storing and Reheating Leftovers

Proper Storage Methods

Cool your leftover pulled pork quickly to prevent bacterial growth. Divide it into smaller portions and refrigerate within two hours of cooking.

Store in airtight containers or zip-top bags, removing as much air as possible. Properly stored, it'll last 3-4 days in the fridge or up to 3 months in the freezer.

Best Reheating Practices

To reheat, add a splash of broth or apple juice to restore moisture. For oven reheating, cover the pork and warm at 250°F until it reaches 165°F internally. Microwave in short bursts, stirring between each, for quick results.

For the best texture, try reheating in a skillet over medium heat, stirring occasionally until warmed through.

Reviving Flavor

Before serving reheated pork, toss it with a bit of fresh rub or BBQ sauce to reinvigorate the flavors. This simple step can make leftovers taste almost as good as fresh off the grill.

Frequently Asked Questions:

1. How long does it take to cook a Boston butt on a gas grill?

Plan for about 1.5 to 2 hours per pound at 225-250°F. A 6-pound butt typically takes 9-12 hours. Remember, always cook to temperature, not time.

2. Should I flip the Boston butt while grilling?

It's not necessary, but you can flip it every 2-3 hours for even cooking. If you do, be gentle to avoid losing juices.

3. Can I use a store-bought rub instead of making my own?

Absolutely! Store-bought rubs work great. Just ensure it complements pork and isn't too salty.

4. How do I know when my Boston butt is done?

Your Boston butt is ready when it reaches an internal temperature of 195-205°F and easily shreds with a fork. Use a reliable meat thermometer for accuracy.

Conclusion

Mastering the art of grilling a Boston butt on your gas grill is a rewarding experience. With patience and attention to detail, you can create mouthwatering pulled pork that'll have your friends and family coming back for seconds.

Remember, the key is low and slow cooking, maintaining a consistent temperature, and letting the meat rest properly.

Don't be discouraged if your first attempt isn't perfect. Each cook is a learning experience, helping you refine your technique.

Experiment with different rubs, wood chips, and serving styles to find your signature flavor. Before long, you'll be the go-to pitmaster in your circle, known for your tender, juicy, and flavorful Boston butt.

Happy grilling!