Over-The-Top Smokehouse Chili

Over-The-Top Smokehouse Chili

By Chef Josh


Smokin Brothers Pellet Grill or similar style smoker

Wire rack (large enough to sit on top of roasting pan)

Large roasting pan

Measuring spoons and cups



Thermoworks One or similar

Sheet tray



1 red pepper

1 yellow pepper

1 orange pepper

1 green pepper

1 large red onion

2 large white onion

Duck Fat spray


3 lbs. 80/20 ground Chuck

1 lb. ground chorizo

1 lb. mild sausage

Meat Seasonings:

2 tsp + extra Twisted Steel Steak Appeal

2 tsp + plus extra Minas Expresso Traditional All-Purpose Coffee Rub

Chili Base:

Duck Fat spray

16 oz red beans

16 oz Cannellini beans or white beans

16 oz black beans

16 oz kidney beans

16 oz pinto beans

60 oz tomato sauce

3 c water for thicker chili (4-5 c for a thinner chili, more water may affect flavors)

1 tsp ground pepper

3 tbs ground cumin

½ c chili powder

2 tbs 100% cocoa powder

¼ tsp ground cayenne

1 tsp oregano

1 tsp salt

2 tbs Twisted Steel Steak Appeal

2 tbs Minas Expresso Traditional All-Purpose Coffee Rub

1 tsp granulated garlic

1 tsp onion powder

¼ c honey

3 tbs light brown sugar

4 tbs Code 3 Spices Backdraft Rub

60 oz unseasoned diced tomatoes

Smokehouse Chili Bundle
All products used have been added to this bundle plus an increased discount.



• Preheat your Smokin Brothers to 400°

Always wash veggies before handling
Always wash veggies before handling

• Cut peppers and onion in sections for the grill

• Spray veggies (vegetables and onions) lightly with Duck Fat spray on both sides

• Place veggies directly on the grill grates

• Grill veggies 15 minutes

• Flip veggies and grill another 10 minutes

• Remove veggies from grill and set aside

• Change grill temperature to 265°


• Break up and loosely combine the chuck, chorizo, and sausage on the cutting board. Add Twisted Steel Steak Appeal and Minas Expresso Traditional All-Purpose Coffee Rub and combine together to form a meat log. Be careful not to over work the meat.

• Lightly season the outside of the log with both rubs on all sides and bottom

• Transfer to the wire rack

• Allow to sweat while preparing Chili base

Chili Base:

• Change grill temp to 265°

• Coat the inside of the roasting pan in Duck Fat spray

• Drain all beans

• Into the roasting pan add tomato sauce, water, pepper, cumin, chili powder, cocoa, cayenne, oregano, salt, Twisted Steel Steak Appeal, Minas Expresso Traditional All-Purpose Coffee Rub, garlic, onion powder, honey, brown sugar, and Code 3 Spices Backdraft; whisk to combine.

• Medium dice the grilled veggies

• Add the veggies, diced tomatoes and drained beans; fold into roasting pan


• Smoke meat log at 265° over chili base

• Using the Thermoworks One probe thermometer verify the internal temperature of the meat log reaches 165°

• The meat log takes approximately 4-5 hours to reach 165°

• Once the meat log reaches temperature carefully take the wire rack with meat log off the grill and rest inside on a sheet tray. Rest meat log 20-30 minutes or until you can handle the meat. Crumble meat, take outside and fold meat into Chili Base.

• Smoke an additional 2-3 hours, stirring every hour to bring all those delicious flavors together.

• Serve hot with your favorite condiments and the chili will be even better the next day! Enjoy!!