Smoked Pulled Pork Chili Recipe Using Leftovers on a Pit Boss

Leftover Smoked Pulled Pork Chili is a cozy, satisfying dish that’s perfect for using up shredded smoked pork. In summer I often smoke pork shoulders and freeze the extra pulled pork; turning those leftovers into a hearty chili is one of my favorite ways to repurpose them.

In the Pacific Northwest, chili isn’t reserved for fall or winter — we get cool days year-round. I smoke this chili in a cast iron Dutch oven on my Pit Boss Pro 1100 and cook it low and slow so the smoke flavor develops deeply. I use mesquite pellets for bold smoke, but use whatever you prefer. If you don’t have a Pit Boss, other pellet grills will do the job just as well.

Leftover Smoked Pulled Pork Chili Ingredients:

• Smoked Pork Shoulder Roast (shredded)
• Canned corn
• Pinto beans
• Chili beans with sauce
• Minced onion
• Cumin
• Garlic powder
• Montreal steak seasoning
• Diced tomatoes
• Beer (I used Pacifico)
• Beef broth

How To Make Leftover Smoked Pulled Pork Chili On A Pit Boss:

1. Prepare the pork: Start with leftover smoked pork and shred it. If the shoulder still has large pieces of fat, you can cut or pull those out and add them to the chili for extra richness.

2. Preheat your smoker: Get the smoker going so it’s producing smoke. I set my Pit Boss Pro 1100 to a medium smoke setting and used mesquite pellets for a pronounced flavor.

If using a cast iron Dutch oven, wipe the interior with a thin layer of oil so ingredients won’t stick. Enameled Dutch ovens work fine, though the exterior enamel can pick up smoke staining.

3. Prep the cans: Open the cans and drain the corn and pinto beans. If your chili beans come in a sauce you like, leave that sauce in — I left the chili beans undrained.

4. Build the chili: Place the shredded pork in the Dutch oven. Add the drained corn and pinto beans, the chili beans with their sauce, diced tomatoes, and minced onion. Season to taste with cumin, garlic powder, Montreal steak seasoning, and any additional chili powder or smoked paprika you like. If your pork has a lot of smoky bark, season more lightly so the chili remains balanced.

5. Add liquids: Pour in a can or bottle of beer and top with beef broth. Stir everything together so the flavors combine evenly.

6. Smoke the chili: Set the uncovered Dutch oven directly on the smoker grates so the smoke can penetrate the chili. Smoke low and slow; stir the chili every 30 minutes to distribute heat and smoke flavor. Aim for at least 3 hours at around 225°F, or smoke longer on a lower smoke setting for more pronounced smoke. In my test I smoked at 200°F for 3 hours, then finished at 225°F.

7. Finish and serve: When the flavors have melded and the chili is hot throughout, remove from the smoker and serve. Top with shredded cheese, sour cream, sliced jalapeños, or a drizzle of sriracha if you like.

If you prefer a thicker chili, whisk together 1/4 cup cornstarch with 1 cup hot water and stir it into the chili about 30 minutes before serving. Alternatively, make a roux of equal parts butter and flour, cook briefly, then stir it in to thicken.

How To Store Leftover Smoked Chili

Transfer the chili to an airtight container and refrigerate for up to five days. For longer storage, freeze in airtight containers for up to three months.

How To Reheat Smoked Chili

Reheat gently on the stove over medium-low heat, stirring occasionally, or microwave in covered portions until heated through. Reheat to a safe serving temperature.

Toppings For Pork Chili

• Shredded cheese
• Sriracha or hot sauce
• Sliced jalapeño
• Sour cream

What To Serve With Smoked Pork Chili

• Tortilla chips
• Mexican or shredded cheese blend
• Saltine crackers
• Sour cream

Other Seasonings and Add-Ins

• Chili powder
• Smoked paprika
• Turmeric (small amounts)
• Sumac (for brightness)
• Seasoning salt
• Liquid smoke (if you want extra smoke without smoking)

Related Smoked Pork Shoulder Recipes

Smoked pork shoulder is versatile and forgiving — there’s no single right way to cook it. If you like this chili, try other smoked pork shoulder recipes such as dry-rubbed shoulders, cola-glazed roasts, or bourbon-flavored variations. Leftover smoked pork also makes excellent fried rice, baked beans, tacos, and sandwiches.

• Dry Rub and Injected Smoked Pork Shoulder Roast
• Coca-Cola Smoked Pork Shoulder Roast
• Jack Daniels and Coke Pork Shoulder Roast
• Apple Bourbon Smoked Pork Shoulder Roast