Description

This isn’t your average, quick-braised beef; this is the ultimate recipe for Smoked Italian Beef Sandwiches. We’re taking a humble chuck roast, giving it a smoky kiss on the outside, and then braising it to “probe tender” perfection in a rich, savory au jus loaded with aromatics. This method creates a depth of flavor that a slow cooker just can’t replicate. It’s a melt-in-your-mouth, juice-drips-down-your-arm kind of sandwich.

Ingredients

For the Smoked Roast:

1 (4 lb) Boneless Chuck Roast
1-2 tbsp Hot Sauce (as binder)
2-3 tbsp Your Favorite Beef Rub

For the Braising Liquid:

3 cups Beef Broth (low-sodium)
1 cup Water
2 tbsp Hot Sauce
1 large White Onion, chopped
6 cloves Minced Garlic
1 cup Tangy Banana Peppers, chopped
1/3 cup Banana Pepper Juice (from the jar)
2 Bay Leaves
2 sprigs Fresh Thyme
2 tbsp Italian Seasoning

For the Spicy Spread:

3 tbsp Mayonnaise
1 tbsp Garlic Paste
1-2 tbsp Hot Sauce (to taste)

For Assembly:

1 pack Hearty French Bread Rolls
1 jar Spicy Giardiniera, for topping

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Instructions

Prep and Season the Roast: Pat your chuck roast dry. Apply a thin layer of hot sauce all over as a binder. Generously season the roast on all sides with your beef rub.
Smoke the Chuck Roast: Preheat your smoker to 250°F (121°C). Place the seasoned roast directly on the smoker grate. Smoke for 3-4 hours, spritzing with beef broth every 45 minutes, until a deep, mahogany-colored “bark” has developed.
Prepare the Braising Bath: In a large Dutch oven, combine the chopped onion, minced garlic, bay leaves, thyme sprigs, chopped banana peppers, banana pepper juice, Italian seasoning, beef broth, water, and 2 tablespoons of hot sauce.
Braise the Roast: Once the roast has its bark, remove it from the smoker and place it directly into the Dutch oven with the braising liquid. Place the uncovered Dutch oven back on the smoker. Increase temperature to 250-275°F (121-135°C). Braise for another 2-3 hours, or until “probe tender” (a thermometer slides in with no resistance).
Rest and Shred the Beef: Carefully remove the roast from the Dutch oven and place it in an aluminum pan. Cover tightly with foil and let it rest for 45 minutes. While it rests, strain the liquid from the Dutch oven into a bowl to serve as your au jus.
After resting, shred the beef using two forks.
Assemble the Sandwich: In a small bowl, whisk together the mayonnaise, garlic paste, and hot sauce to create the spicy spread. Slice your French bread rolls (not all the way through) and toast them lightly.
Slather the spicy spread on the bun, load it with the warm shredded beef, and top it with a spoonful of giardiniera. Serve each sandwich with a side of the warm au jus for dipping.

Notes

Spritzing: To keep the surface moist, spritz the roast with beef broth or apple cider vinegar every 45 minutes or so during the initial smoke.
“Probe Tender”: The roast is done when a meat thermometer or skewer slides into the thickest part of the beef with almost no resistance (like probing a bag of flour).
Resting is Crucial: This is the most important step for a juicy sandwich! Letting it rest for 45 minutes allows the muscle fibers to relax and reabsorb all those delicious juices.
Au Jus: Don’t discard the braising liquid! Strain it and serve it as a warm dipping sauce.

Prep Time: 20 minutes
Cook Time: 6 hours
Category: Main Course, Sandwich
Method: Smoking, Braising
Cuisine: American, Italian-American

Nutrition

Serving Size: 1 sandwich
Calories: 780 kcal
Sugar: 4 g
Sodium: 1200 mg
Fat: 45 g
Saturated Fat: 15 g
Unsaturated Fat: 30 g
Trans Fat: 0 g
Carbohydrates: 42 g
Fiber: 3 g
Protein: 48 g
Cholesterol: 150 mg