How Long To Smoke A 4 Lb Pork Butt: A Detailed Guide For Perfect Pulled Pork

Smoking a pork butt to make pulled pork is one of the most satisfying ways to use your pellet grill The savory, succulent meat that results from low and slow smoking is a crowd-pleaser, but smoking a pork butt does require some time and technique If you’ve got a 4 lb pork butt, about how long will it take to smoke it to perfection? Let’s walk through everything you need to know.

How Long Does It Take To Smoke A 4 Lb Pork Butt?

For a 4 lb boneless pork butt, you can expect the total cook time to be around 4-6 hours at 250°F. This includes the time for the pork to get through the stall phase. A bone-in pork butt of the same size may take closer to 6-8 hours since the bone acts as an insulator.

The general guideline is to estimate 1-1.5 hours per pound, but there are many factors that affect cook time. The shape and thickness of your particular pork butt, the temperature outside, and the accuracy of your grill temperature probe can all impact the timeline. The only foolproof way to know when your pork butt is done is to use a meat thermometer.

Here is a timeline of what to expect when smoking a 4 lb pork butt:

• 1-2 hours: The pork butt will heat from room temperature to around 150°F. You’ll see a steady rise in temperature during this phase.

• 2-4 hours The pork butt will hit the “stall” phase around 150-160°F. This is when moisture evaporates from the surface and causes the temperature to plateau The meat may hold steady around 150°F for a couple hours or more Be patient!

• 1-3 hours: Once the pork butt pushes past the stall, the temperature will begin steadily rising again until it reaches 195-205°F for slicing or pulling.

• Rest time:Let the pork butt rest for 30-60 minutes before pulling or slicing. This allows the juices to redistribute.

So in total, you’re looking at a range of 4-6 hours for a 4 lb boneless pork butt and potentially up to 8 hours for a bone-in roast. But always rely on the internal temp and tenderness of the meat rather than the clock.

Choosing The Right Size Pork Butt

• For pulled pork sandwiches, plan on 1/3 lb of finished pulled pork per person.

• Since you lose about 30% of the raw weight during cooking, buy 1/2 lb of raw pork per person.

• For a 4 lb raw pork butt, expect about 2-3 lbs of finished pulled pork or enough for 6-9 people.

• For a smaller gathering, choose a 2 lb or 3 lb pork butt. Go larger for a big crowd.

• It’s better to have leftovers than to run out of this delicious meat! Refrigerate for up to 4 days or freeze pulled pork for later.

Preparing The Pork Butt

Follow these tips for getting your pork butt ready for the smoker:

• Choose a pork butt roast, also called a Boston butt. Don’t confuse this with the ham-like picnic roast from the lower shoulder.

• Leave the fat cap on for moisture, flavor, and bark development. Just trim off any large flap areas.

• Apply a dry rub all over the pork butt. Let it sit for at least 30 minutes before smoking for enhanced flavor penetration.

• Use a meat injector to inject extra flavor if desired. Try apple juice, broth, or your favorite barbecue sauce.

• For even more flavor, brine or marinate the pork butt overnight in the fridge.

How To Smoke A Pork Butt In 5 Easy Steps

Follow this simple process for perfect pulled pork every time:

1. Preheat The Smoker

• Heat your pellet grill or smoker to 250°F.

• Use a smoking wood like hickory, maple, cherry, or apple.

• Let it preheat for 15-30 minutes before adding the pork.

2. Add The Pork Butt

• Place the seasoned pork butt fat side up on the cooking grate.

• Insert a probe thermometer into the thickest part, avoiding bone.

3. Smoke Until Stall

• Let the pork butt smoke until it hits around 150°F. This takes 1-2 hours.

• At this point, spritz with apple juice or broth if desired.

4. Wrap And Continue Cooking

• Once the pork stalls around 150°F, wrap it tightly in foil.

• Return to the grill until 205°F internal temperature.

5. Rest And Pull

• When the pork butt reaches 205°F, remove from heat.

• Let rest wrapped for 30-60 minutes before pulling.

• Pull into shreds using two forks. Enjoy!

Handling The Stall For Tender Pulled Pork

The stall during smoking is when the meat temperature hits a plateau around 150-170°F and seems to stop rising. This happens as moisture evaporates from the surface. It can last 1-3 hours. Here are 3 ways to power through:

• Be patient! Don’t increase the heat. Let it ride out the stall for juicy pulled pork.

• Spritz with apple juice or broth to add moisture if it stalls longer than 3 hours.

• Wrap in butcher paper or foil to help push past the stall. This powers through but reduces bark.

Waiting out the stall results in the most tender, juicy pulled pork so try to be patient. But wrapping can accelerate it if you’re in a time crunch.

Signs Your Pork Butt Is Done

Rely on these cues, not the clock, to know when your pork butt is ready to pull:

• The internal temp hits 200-205°F. Use a leave-in thermometer for easy monitoring.

• A meat probe or fork slides in with little resistance.

• The meat shreds easily when poked.

• The bone (if bone-in) wiggles freely when rotated.

• The outside bark is dark and crusty.

Don’t let the time frame worry you. Focus on tenderness and temp. At 205°F or when probe tender, it’s time to pull off the heat.

Resting & Pulling For Juicy Pork

Resting and proper pulling ensures your pork stays juicy:

• Rest the pork butt for 30-60 minutes before pulling. This allows juices to reabsorb.

• Pull the hot pork by hand into shreds and pieces, discarding excess fat.

• Pour any resting juices from the foil over the pulled pork to keep it moist.

• For easy pulling, use two forks to shred the pork or place in a stand mixer on low speed.

• Try not to break up the crispy bark too much as you pull the meat.

• Serve the juicy pulled pork piled high on buns or nachos! Enjoy right away or store leftovers.

Storing And Reheating Leftover Pulled Pork

• Refrigerate leftover pulled pork for up to 4 days.

• Freeze pulled pork for 1-3 months in an airtight container. Thaw before using.

• Reheat pulled pork in the microwave in 30 second bursts until warmed through.

• For best results, reheat in a skillet with barbecue sauce or broth to add moisture. Simmer on the stovetop until heated through.

Infuse Flavor With Rubs, Marinades And Sauces

• Dry rub the pork butt just before smoking for flavorful bark. Try Perfect Pork Rub or Pork & Poultry Rub.

• Inject pork butt with apple juice, broth, or barbecue sauce for extra moisture and flavor.

• Marinate for 24 hours for seasoned meat. Go bold with a Mexican mojo marinade.

• During the stall is a great time to spritz with more marinade or apple juice.

• Toss hot pulled pork with your favorite barbecue sauce before serving. Sweet and smoky flavors pair perfectly.

With the right preparation and handling of the smoking stages, you can turn out amazing smoked pulled pork from a 4 lb pork butt using your pellet grill. Focus on tenderness and temperature, relax through the stall, and rest before pulling for juicy, succulent meat. Now get smoking and enjoy your own delicious pulled pork!