Phase 1: Preparing and Smoking the Meats (Approx. 2-3 hours)

1. Prepare the Smoker: Preheat your smoker to 225-250°F (107-121°C). Add your chosen wood chunks/chips according to your smoker’s instructions to generate a steady stream of clean smoke.
2. Season the Meats: In a large bowl, combine the cubed chuck roast, ground beef (gently broken up), and pork sausage. Drizzle lightly with olive oil if your rub doesn’t have much oil-binding capability. Generously apply your BBQ rub, ensuring all pieces are evenly coated. Let it sit for at least 30 minutes at room temperature, or up to a few hours covered in the refrigerator.
3. Smoke the Meats: Arrange the seasoned meats in a single layer on smoker-safe wire racks or directly on the smoker grates. If using ground meat and sausage, you can place them on a perforated pan or fine mesh rack to prevent them from falling through. Smoke for 1.5 – 2 hours, or until the chuck roast has developed a nice bark and the internal temperature reaches around 150-160°F (65-71°C). The ground meat and sausage should be cooked through. The goal here is flavor infusion, not full tenderness for the chuck roast yet.
4. Rest and Prepare Meats: Remove the meats from the smoker. Let the chuck roast rest for about 15-20 minutes, then dice it into smaller, bite-sized pieces (about 1/2 to 3/4 inch). Roughly chop or crumble the smoked ground beef and sausage. Set all smoked meats aside.

Phase 2: Building the Chili Base (Approx. 30-45 minutes)

1. Sauté Aromatics: In a very large, heavy-bottomed Dutch oven or stockpot (one that can ideally go into the smoker later, or you’ll need a smoker-safe pan to transfer to), heat the 2 tablespoons of olive oil or beef tallow over medium-high heat. Add the diced onions and bell peppers. Sauté for 8-10 minutes, stirring occasionally, until softened and lightly caramelized.
2. Add More Aromatics: Add the minced jalapeños and garlic to the pot. Cook for another 2-3 minutes until fragrant, being careful not to burn the garlic.
3. Brown Tomato Paste & Bloom Spices: Push the vegetables to one side of the pot. Add the tomato paste to the cleared space and cook for 2-3 minutes, stirring constantly, until it darkens slightly. This caramelizes the paste and deepens its flavor. Then, add the chili powder, smoked paprika, cumin, oregano, cayenne pepper, cocoa powder, and black pepper directly to the pot. Stir them into the vegetables and tomato paste, cooking for 1-2 minutes until fragrant. This “blooming” of the spices enhances their flavor.
4. Incorporate Meats: Add all the reserved smoked meats (diced chuck, crumbled ground beef, and sausage) to the pot. Stir well to coat the meat with the spices and aromatics. Cook for 5-7 minutes, allowing the flavors to meld.

Phase 3: Simmering and Developing Flavors (Approx. 1 hour on stovetop + 2-3 hours smoking)

1. Deglaze and Add Liquids: Pour in the dark beer (if using) and scrape up any browned bits (fond) from the bottom of the pot with a wooden spoon – this is pure flavor! Let it simmer for a few minutes to reduce slightly.
2. Add Tomatoes and Broth: Stir in the diced tomatoes (undrained), crushed tomatoes, and Worcestershire sauce. Add 2 cups of beef broth. Bring the mixture to a gentle simmer.
3. Initial Simmer (Stovetop): Reduce the heat to low, cover the pot, and let the chili simmer gently on the stovetop for at least 1 hour, stirring occasionally. This allows the initial flavors to meld. If the chili becomes too thick, add a bit more beef broth.
4. Add Beans (Optional): If using beans, stir in the rinsed and drained kidney beans and pinto/black beans.
5. Taste and Adjust Seasoning: Taste the chili. Add kosher salt as needed. Remember that flavors will concentrate further during smoking. You might also want to adjust other spices.
6. Smoke the Chili:

   • Ensure your smoker is still maintaining 225-250°F (107-121°C) with clean smoke.
   • Transfer the chili to the smoker. If your Dutch oven is smoker-safe, place it directly on the grates, uncovered. If not, transfer the chili to a large, disposable aluminum pan or another smoker-safe baking dish.
   • Smoke the chili for 2-3 hours, stirring every 45-60 minutes. This allows the smoke to permeate the entire batch and the flavors to deepen profoundly. Keep an eye on the liquid level; if it reduces too much, add a splash more beef broth.

7. Final Touches: After smoking, remove the chili from the smoker. Stir in the apple cider vinegar – this brightens up all the rich, smoky flavors. If you opted for liquid smoke and feel it needs an extra touch, add it now. Taste one last time and adjust seasonings if necessary.

Phase 4: Resting (Crucial!)

1. Rest the Chili: Allow the chili to rest for at least 30 minutes before serving. Even better, let it cool completely, refrigerate overnight, and reheat the next day. The flavors will meld and deepen even further, resulting in an even more incredible chili.