How To Grill A Juicy, Tender Boston Butt Pork Roast: A Step-By-Step Guide

Boston butt, also known as pork butt or pork shoulder, is a flavorful and inexpensive cut of pork that’s perfect for grilling. When cooked low and slow over indirect heat, this tough cut becomes incredibly tender and juicy with a deliciously smoky flavor

Grilling a whole bone-in Boston butt may seem intimidating, but it’s actually quite easy with the right techniques. In this guide, we’ll walk through the foolproof process of grilling a mouthwatering Boston butt pork roast from start to finish. Let’s get grilling!

What is Boston Butt?

Boston butt is not actually the rear end of the pig as the name implies. It comes from the upper shoulder of the hog and contains parts of both the shoulder blade and upper arm.

This well-marbled cut is known for its rich, beefy flavor and high collagen content which breaks down into gelatin when cooked low and slow. The bone-in variety has more flavor. Plan on cooking times of 1-1.5 hours per pound.

Benefits of Grilling Boston Butt

While Boston butt is often smoked or slow roasted grilling offers some advantages

• Added smoke flavor – The pork absorbs great smoky taste from the grill.

• Direct caramelization – The hot grill sears the exterior developing a crispy bark.

• Easier temperature control – Unlike an oven, you can adjust heat as needed.

• Self bastes – Pork juices vaporize on the grill for automatic basting.

• Hands-off – Once setup, you don’t need to watch it as closely as in the oven.

How to Choose a Boston Butt

When selecting a Boston butt for grilling, keep these tips in mind:

• Bone-in provides better flavor and moisture. Opt for bone-in over boneless.

• Weight – Choose a 5 to 7 pound roast for easier grilling. Larger cuts take much longer.

• Marbling – Look for liberal marbling throughout for tenderness and juiciness.

• Shape – Pick a uniform shape over irregular for even cooking.

• Freshness – Be sure the pork has good color and scent with no dull or slimy spots.

Grilling Tools Needed

Having the right grilling tools on hand will make the process much easier:

• Gas or charcoal grill with lid
• Instant read thermometer
• Large disposable foil pan
• Wood chips or chunks (mesquite, hickory, apple)
• Grill brush
• Tongs
• Oven mitts
• Basting brush
• Cooler (for resting)

Step-By-Step Guide

Follow these simple steps for perfect grilled Boston butt pork roast:

1. Prep the Meat

• Pat the pork dry and trim off any loose fat or skin. Apply a light coat of oil.

• Generously season all over with dry rub. Get into creases and underside.

• Allow meat to come to room temperature while you prep grill.

2. Prep the Grill

• If using charcoal, light a full chimney starter and build a two-zone fire, with coals piled on one side.

• For gas, turn one burner to high and leave adjacent burners off.

• Place a disposable foil pan on the unlit side and fill with water. This will regulate heat.

• Add your choice of wood chips or chunks to coals/burner to generate smoke.

3. Sear the Roast

• With the grill preheated to medium heat (350°F), carefully place the pork over direct heat on the grates, bone-side down.

• Sear for 2-3 minutes until a nice crust forms. Turn to sear all sides until browned.

4. Grill Indirectly

• Move pork to indirect heat on the foil pan’s side, bone-side up.

• Maintain grill at medium-low heat (225-250°F) with vents open. Close the lid.

• Check periodically and add more coals/wood to maintain the temperature if needed.

5. Baste and Continue Cooking

• After the first hour, start basting the pork every 30 minutes with barbecue sauce.

• Insert a probe thermometer into thickest part, keeping probe as centered as possible.

• Continue cooking until it reaches an internal temp of 195-203°F. Expect 1-1.5 hours per pound.

6. Rest, Slice and Serve

• Transfer pork to a cooler, wrap in a towel and let rest for 30-60 minutes. This allows juices to reabsorb.

• Remove bone and slice or shred meat as desired. Serve drizzled with pan juices and more barbecue sauce.

• Enjoy on sandwiches, over mac and cheese, stuffed in tacos – the possibilities are endless!

Tips and Variations

• Apply a dry rub the night before for extra flavor penetration.

• Use apple, cherry, pecan or hickory wood for optimal smoke flavor.

• Wrap in foil during stall phase (160-170°F) to power through and speed up cooking.

• For crackling skin, remove bone, score rind and grill meat-side down after searing.

• Serve with traditional barbecue sides like baked beans, coleslaw and cornbread.

Common Questions

What is the safe internal temperature for grilled pork?

The USDA recommends cooking pork to a minimum internal temperature of 145°F. For Boston butt, cook to 195-203°F for proper shredding.

How long per pound should you grill a Boston butt?

In general, grill Boston butt for about 1 hour 15 minutes per pound at 225-250°F indirect heat. A 7 pound roast will take around 9-10 hours.

Is Boston butt done when the bone pulls out?

Don’t rely on the bone pulling out easily to determine doneness. Always check the internal temp, as it can reach 205°F and still have some resistance. Cook until 195-203°F.

Can you grill a boneless pork butt roast?

Yes, bone-in is ideal but boneless will work too. Just monitor the internal temperature closely and watch for drying out without the bone. Cook to 203°F.

Should you wrap pork butt in foil on the grill?

Wrapping during the stall phase (160-170°F) speeds up cooking. But it’s optional – you’ll get great results without wrapping too.

Inspiring Recipe Ideas

The possibilities are endless when grilling juicy, smoky Boston butt pork roast. Get inspired with these ideas:

• Chili-Rubbed Pulled Pork with Lime Crema

• Jamaican Jerk Pork Roast with Grilled Pineapple

• Korean BBQ Pulled Pork Sliders with Kimchi

• Memphis Dry Rub Pork with Bourbon BBQ Sauce

• Porchetta Style Pork Roast with Herb Salsa Verde

• Harissa & Honey Glazed Pork with Mint Yogurt Dip

• Cuban Mojo Pork Shoulder with Black Beans & Rice

The tender, flavorful meat also shines in soups, stews, nachos, tacos, sandwiches and more!

Conclusion

Grilling a mouthwatering Boston butt pork roast may seem intimidating to newcomers, but it’s actually quite simple with this easy step-by-step guide. With the right prep, tools and techniques, you can produce incredibly juicy, smokey pulled pork that rivals any BBQ joint.

The keys are selecting a well-marbled bone-in roast, cooking low and slow over indirect grill heat, monitoring the temperature and resting the meat properly before serving. Feel free to get creative with worldly rubs and sauces too.

Impress your family with your grilling skills by making this succulent roast. Just be prepared to become the neighborhood’s new go-to grill master!