Smoked Chuck Roast French Dip Sandwiches

Step-by-step instructions.

1. Preheat and season the chuck roast

   • Preheat the smoker or pellet grill to 450°F with the lid closed. Pat the roast dry and coat lightly with olive oil. Mix the roast salt, pepper, garlic powder, and onion powder, then season every side.
   • Use chuck roast for this recipe, allowing several hours for the connective tissue to soften. Time varies with thickness and the individual roast.

2. Sear at 450°F

   • Place the roast directly on clean grill grates and cook at 450°F for approximately 15–25 minutes total, turning halfway through, until the outside develops a deep brown crust. Watch closely for flare-ups and move away from hot spots as needed.
   • A pellet grill may brown more gently than a direct-flame grill. Judge the crust by appearance rather than extending this stage until the meat dries out.

3. Lower to 325°F and finish covered

   • While the roast browns, combine the beef broth, Worcestershire sauce, thyme, smashed garlic, and bay leaf in a Dutch oven or deep smoker-safe metal roasting pan.
   • Reduce the smoker to 325°F. Transfer the browned roast into the broth; liquid should come roughly one-third to halfway up the meat, not submerge it. Adjust pan size or broth as needed. Cover tightly with a lid or foil and return to the smoker.
   • Cook for about 2½–4 hours, checking after 2 hours. Add hot broth if the pan becomes low. Begin checking tenderness around 190°F; the roast is ready when a probe slides into the thickest part with little resistance, often around 195–205°F. Temperature is a guide, not a substitute for tenderness.

4. Sauté the onions near the end of the cook

   • When the roast is approaching tenderness, melt the butter in a large skillet over medium heat. Add the sliced onions and ¼ teaspoon salt.
   • Cook for 20–25 minutes, stirring regularly, until softened and golden. Reduce the heat if they brown too quickly, and add a splash of water to loosen any browned bits. Keep warm.

5. Rest the beef and finish the au jus

   • Move the tender roast to a board, loosely tent, and rest for 20–30 minutes.
   • Strain the cooking liquid into a saucepan, discarding the bay leaf and garlic. Skim excess fat. Simmer for 5–10 minutes if it needs more concentration, or dilute with broth or water if too salty. Taste before adding any extra seasoning. Reserve about ½ cup for moistening the beef and serve the remaining jus hot for dipping.
   • Slice the roast thinly across the grain, changing direction where muscle seams change. If very tender pieces fall apart, use them as pulled beef. Toss gently with the reserved jus.

6. Toast, assemble, and melt the cheese

   • Toast the split rolls cut-side up under an oven broiler for 1–2 minutes, watching constantly. Divide the warm beef among the bottom halves and top with sautéed onions and provolone.
   • Broil the open sandwiches for another 1–2 minutes, just until the cheese melts. Keep the top rolls out during this step so they do not burn. Alternatively, melt the cheese on a tray in the covered smoker at 325°F for about 5–10 minutes.

7. Serve with au jus

   • Close the sandwiches and serve immediately with individual bowls of hot au jus. Dip as you eat to keep the bread from becoming soggy.