Part 1: Smoking the Chuck Roast

1. Prepare the Chuck Roast: Pat the chuck roast dry with paper towels. This helps the rub adhere better and promotes a better crust.
2. Apply the Dry Rub: In a small bowl, combine the kosher salt, black pepper, garlic powder, onion powder, paprika, and cayenne pepper (if using). Mix well to ensure all spices are evenly distributed. Generously rub the spice mixture all over the chuck roast, ensuring all surfaces are coated. This dry rub will season the meat and create a flavorful bark during smoking.
3. Dry Brine (Optional but Recommended): For even better flavor and moisture retention, wrap the seasoned chuck roast loosely in plastic wrap and refrigerate for at least 4 hours, or preferably overnight. This dry brining process allows the salt to penetrate the meat, tenderizing it and enhancing its flavor.
4. Prepare Your Smoker: Preheat your smoker to 225-250°F (107-121°C). Prepare your smoker according to the manufacturer’s instructions. If using a charcoal smoker, light your coals and allow them to reach the desired temperature, adding wood chips or chunks for smoke. If using a pellet smoker or electric smoker, set the temperature and hopper with your chosen wood pellets or chips.
5. Smoke the Chuck Roast: Place the chuck roast directly on the smoker grates. Insert a meat thermometer into the thickest part of the roast, avoiding any bone or fat pockets. Smoke the chuck roast for approximately 6-8 hours, or until the internal temperature reaches 195-205°F (90-96°C). This temperature range is crucial for breaking down the connective tissue in the chuck roast and achieving that fall-apart tender texture.
6. Maintain Smoke and Temperature: Throughout the smoking process, maintain a consistent smoker temperature between 225-250°F (107-121°C). Add wood chips or chunks as needed to maintain a steady stream of smoke. Monitor the internal temperature of the roast regularly.
7. Check for Tenderness: Once the internal temperature reaches 195-205°F (90-96°C), check for tenderness by inserting a probe or fork into the roast. It should slide in easily with minimal resistance. If it still feels tough, continue smoking until it reaches the desired tenderness. The “probe tender” feel is more important than hitting an exact temperature.
8. Rest the Chuck Roast: Once the chuck roast is tender, remove it from the smoker and wrap it tightly in butcher paper or aluminum foil. Let it rest for at least 1 hour, or up to 2 hours. Resting allows the juices to redistribute throughout the meat, resulting in a more tender and flavorful final product.
9. Shred or Cube the Smoked Chuck Roast: After resting, unwrap the chuck roast. Using two forks, shred the roast into bite-sized pieces. Alternatively, you can cube it if you prefer chunkier chili. Set aside the smoked chuck roast; it’s now ready to be added to the chili.

Part 2: Preparing the Chili

1. Sauté Aromatics: In a large, heavy-bottomed pot or Dutch oven, heat the olive oil over medium heat. Add the chopped onion and bell peppers and sauté for 5-7 minutes, or until the onions are softened and translucent and the peppers are slightly tender. Stir occasionally to prevent sticking.
2. Add Jalapeños and Garlic: Add the minced jalapeño peppers and garlic to the pot. Sauté for another 1-2 minutes, until fragrant. Be careful not to burn the garlic, as it can become bitter.
3. Bloom the Spices: Add the chili powder, cumin, ancho chili powder, smoked paprika, and dried oregano to the pot. Cook for 1 minute, stirring constantly, until fragrant. This process, called “blooming,” helps to release the essential oils in the spices and intensify their flavor.
4. Add Tomatoes and Tomato Sauce: Pour in the crushed tomatoes, diced tomatoes (undrained), and tomato sauce. Stir well to combine with the spices and vegetables. Bring the mixture to a simmer.
5. Incorporate Smoked Chuck Roast and Beans: Add the shredded or cubed smoked chuck roast, kidney beans, black beans, and pinto beans (if using) to the pot. Stir to combine all ingredients thoroughly.
6. Add Broth and Seasonings: Pour in the beef broth or stock. Stir in the cocoa powder and brown sugar. Season with salt and black pepper to taste. Remember that the smoked chuck roast and canned beans may already contribute some salt, so season gradually.
7. Simmer the Chili: Bring the chili back to a simmer, then reduce the heat to low, cover the pot, and simmer for at least 1-2 hours, or up to 3 hours for even deeper flavor development. Stir occasionally to prevent sticking and to ensure even cooking. The longer simmering time allows the flavors to meld together beautifully and the chili to thicken.
8. Adjust Consistency and Seasoning: During the simmering process, check the consistency of the chili. If it becomes too thick, add a little more beef broth or water to reach your desired consistency. Taste and adjust seasonings as needed. You may want to add more salt, pepper, chili powder, or other spices to achieve your preferred flavor profile.
9. Serve: Once the chili has simmered to your liking, it’s ready to serve! Ladle the Smoked Chuck Roast Chili into bowls and offer a variety of your favorite chili toppings (see “How to Serve” section below).