Hickory-Smoked Pulled Pork Sandwiches with House BBQ Sauce

By , Test Kitchen Director · Reviewed by AislePrompt Editorial · ·

Tender hickory-smoked pulled pork served on toasted buns, slathered with a sweet and smoky house barbecue sauce. This american-inspired bbq & smoked ready in about 1200 minutes blends pounds pork shoulder (bone-in), kosher salt, black pepper into a versatile sauce that lifts everything from grain bowls and roasted vegetables to grilled proteins — a small-batch staple worth keeping in the fridge. Each serving lands at about 650 calories and feeds 8, so a small batch covers several meals across the week without taking over the fridge. Tap "Plan a meal with the AI" below to drop this recipe into your week and send the ingredients straight to Instacart. Nutrition values are approximate, calculated from USDA FoodData Central (fdc.nal.usda.gov) — verify against ingredient labels for any health-driven dietary plan.

Prep: 480 min Cook: 720 min Serves 8 American cuisine 650 cal/serving
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Ingredients

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Instructions

  1. Step 1: In a small bowl, mix 2 tbsp kosher salt, 1 tbsp black pepper, 3 tbsp brown sugar, 2 tbsp smoked paprika, and 1 tbsp garlic powder. Rub this spice blend thoroughly over the entire 5-pound pork shoulder. Let rest uncovered in the refrigerator for at least 4 hours or overnight.
  2. Step 2: Prepare your smoker to 225°F and add 5 handfuls of soaked hickory wood chips to generate smoke.
  3. Step 3: Place the pork shoulder on the smoker grate and smoke for 10-12 hours until the internal temperature reaches 200°F and the meat is tender enough to pull apart easily.
  4. Step 4: While the pork smokes, combine 1/2 cup yellow mustard, 1/2 cup ketchup, 1/4 cup apple cider vinegar, 2 tbsp molasses, and 1 tbsp Worcestershire sauce in a saucepan. Simmer over medium heat for 10 minutes until thickened slightly.
  5. Step 5: Remove the pork from the smoker and let it rest for 30 minutes. Shred the meat with two forks, discarding excess fat.
  6. Step 6: Toast 8 hamburger buns until golden. Pile each bun with 1/2 cup of pulled pork and drizzle generously with house BBQ sauce before serving.

Frequently asked questions

How long does Hickory-Smoked Pulled Pork Sandwiches with House BBQ Sauce take to make?

Total time is about 1200 minutes (480 min prep + 720 min cook). A small batch typically covers several meals in the week — store as the recipe directs.

How do I store leftover Hickory-Smoked Pulled Pork Sandwiches with House BBQ Sauce?

Transfer to an airtight jar and refrigerate for up to 5–7 days. Most sauces freeze well for up to 2 months — portion into small containers or freezer bags so you can thaw only what you need. Stir before serving; cream- or yogurt-based sauces may separate on standing.

Can I substitute ingredients in Hickory-Smoked Pulled Pork Sandwiches with House BBQ Sauce?

Yes — most ingredients in this recipe have flexible swaps. For oil, use any neutral high-smoke-point oil (avocado, grapeseed, refined coconut). For aromatics, dried herbs at ⅓ the volume of fresh work in a pinch. The full ingredient list is shoppable on Instacart so you can see substitutes in real time.

How do I scale Hickory-Smoked Pulled Pork Sandwiches with House BBQ Sauce for a different number of people?

The recipe is written for 8 servings. Multiply each ingredient by (your serving target / 8). Cook time stays roughly the same up to 2x; for 3-4x batches, switch from a skillet to a sheet pan or stockpot so the food isn't crowded — overcrowding steams instead of browns.

What goes well with Hickory-Smoked Pulled Pork Sandwiches with House BBQ Sauce?

American bbq & smoked like this pair well with a simple grain (rice, couscous, or crusty bread), a quick salad with acid (lemon vinaigrette, pickled onions), and a pan sauce or yogurt-based dip. Tap "Plan a meal with the AI" to get specific side suggestions.

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