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Step-by-step instructions.
Season the roast
Preheat the smoker to 250°F. Trim hard exterior fat from the chuck. Coat lightly with mustard, then season with salt, pepper, paprika, and garlic powder.
Build the bark
Smoke the whole roast for about 3–4 hours until the surface is dark and the seasoning no longer wipes away easily, often around 165–175°F internal. These are wrapping cues, not the finish line.
Braise until nearly tender
Place in a heat-safe pan with broth and cover tightly with foil. Continue at 250°F for about 1½–2 hours until a probe slides in with only slight resistance. Add time if it still feels tight.
Cube and glaze
Rest 10 minutes, keeping the pan juices. Cut into roughly 1-inch cubes, discarding large fat pockets. Toss with BBQ sauce, sugar, butter, and a few spoonfuls of the defatted juices.
Set the sauce
Return uncovered to the smoker at 275°F for 30–60 minutes. Stir once or twice. Finish when the glaze clings and the cubes are tender; a probe should slide in easily, often around 200–205°F. Add a splash of juices if the sauce dries before the beef softens.
Finish when the chuck is probe-tender, often around 200–205°F. Check the thickest part with a thermometer, away from bone or the hot pan.
USDA temperature guidance

