Smoked Pork Shoulder Cold Cuts for Charcuterie Boards

Quick Recipe Version (TL;DR)

• Yield: About 18–20 servings (thinly sliced cold cuts, 2 oz / 60 g each)
• Prep Time: 45 minutes active (plus brining and chilling)
• Cook Time: 6–8 hours
• Total Time: 1½–2 days (including 12–24 hours brining and overnight chilling)

Quick Ingredients

• 4–5 lb (1.8–2.3 kg) boneless pork shoulder (pork butt)
• 1 gallon (3.8 L) water
• 150 g kosher salt (about 3/4 cup Diamond Crystal)
• 100 g light brown sugar (about 1/2 cup, packed)
• 5 garlic cloves, smashed
• 2 bay leaves
• 2 tsp black peppercorns
• Dry rub: 2 tbsp brown sugar, 1 tbsp paprika, 2 tsp black pepper, 1 tsp mustard powder, 1 tsp garlic powder, 1 tsp onion powder
• 2–3 cups wood chips or 4–6 chunks mild smoking wood (apple, cherry, or maple)

Do This

• 1. Make brine: simmer half the water with salt, sugar, garlic, bay, and peppercorns until dissolved; add remaining water and chill completely.
• 2. Submerge pork in cold brine, refrigerate 12–24 hours, turning once halfway if needed.
• 3. Rinse briefly, pat very dry, coat with dry rub, and refrigerate uncovered on a rack at least 1 hour (up to overnight) to dry the surface.
• 4. Preheat smoker (or grill set for indirect heat) to 225°F (107°C). Add wood.
• 5. Smoke pork shoulder 6–8 hours until internal temperature is 180–185°F (82–85°C) and tender but still sliceable.
• 6. Rest 20–30 minutes at room temperature, then refrigerate until completely chilled, at least 8 hours or overnight.
• 7. Slice very thin across the grain and serve chilled as a cold cut, or store tightly wrapped in the fridge.

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Why You’ll Love This Recipe

• Deeply seasoned from an overnight brine, so every bite is juicy and flavorful all the way through.
• Slow-smoked for gentle, balanced smoke that complements the pork instead of overpowering it.
• Chilled and sliced paper-thin, just like a deli meat, for beautiful charcuterie boards and sandwiches.
• Perfect make-ahead project: one long smoke day gives you a week’s worth of incredible cold cuts.

Grocery List

• Produce: Garlic (at least 5–7 cloves)
• Dairy: None required
• Pantry: Boneless pork shoulder, kosher salt, light brown sugar, black peppercorns, bay leaves, paprika, garlic powder, onion powder, dry mustard (or mustard powder), optional whole-grain mustard, pickles, crusty bread or crackers, mild smoking wood (apple, cherry, or maple)

Full Ingredients

Pork

• 1 boneless pork shoulder (also called pork butt), 4–5 lb (1.8–2.3 kg), well-marbled

Brine

• 1 gallon (3.8 L) cold water
• 150 g kosher salt (about 3/4 cup Diamond Crystal; if using Morton’s, use 1/2 cup and weigh if possible)
• 100 g light brown sugar (about 1/2 cup, packed)
• 5 garlic cloves, smashed
• 2 bay leaves
• 2 tsp whole black peppercorns
• 1 tsp mustard seeds (optional, for subtle tang)

Dry Rub (No Extra Salt)

• 2 tbsp light brown sugar
• 1 tbsp sweet paprika (regular or Hungarian)
• 2 tsp freshly ground black pepper
• 1 tsp garlic powder
• 1 tsp onion powder
• 1 tsp dry mustard (mustard powder)
• 1/2 tsp smoked paprika (optional, for extra smoky depth)

For Smoking & Optional Serving

• 2–3 cups wood chips or 4–6 chunks mild fruit wood (apple, cherry, or maple are ideal)
• 1–2 tbsp neutral oil (such as canola) or light olive oil, for rubbing on the pork if needed
• Whole-grain mustard, Dijon, or spicy brown mustard (for serving, optional)
• Pickles, pickled onions, or cornichons (for serving, optional)
• Crusty bread, baguette slices, or crackers (for serving, optional)

Step-by-Step Instructions

Step 1: Plan ahead and trim the pork

This recipe takes a bit of calendar time, so it is best to start at least one full day before you want to serve the cold cuts.

Unwrap the pork shoulder and pat it dry with paper towels. Using a sharp knife, trim off any loose flaps of meat or excessively thick, hard fat. Leave a good 1/4 inch (about 6 mm) fat cap if your cut has one; this will help keep the meat moist and adds flavor. If there is silver skin (thin, shiny membrane), carefully slide the tip of your knife under it and peel it away, similar to trimming ribs.

We want the roast reasonably compact for even cooking. If there are any deep pockets or flaps, you can tie the shoulder with kitchen twine into a neat, firm cylinder. This is optional but can give nicer, more uniform slices later.

Step 2: Make and chill the brine

In a large pot, add about half of the water (2 quarts / 1.9 L), the kosher salt, brown sugar, smashed garlic cloves, bay leaves, black peppercorns, and mustard seeds (if using). Bring just to a gentle simmer over medium heat, stirring until the salt and sugar are completely dissolved. You do not need a rolling boil; once everything is dissolved and fragrant, remove the pot from the heat.

Add the remaining cold water (2 quarts / 1.9 L) to the pot to cool the brine more quickly. Stir well. To be safe, the brine must be completely cold (at or below 40°F / 4°C) before adding the pork. If needed, add a few handfuls of ice and stir until fully melted, then discard any unmelted ice so the water ratio stays correct.

Step 3: Brine the pork shoulder (12–24 hours)

Place the trimmed pork shoulder into a large non-reactive container (glass, food-grade plastic, or stainless steel). A deep food storage container or a large zip-top brining bag set in a bowl works well. Pour the fully cooled brine over the pork, making sure it is completely submerged. If it wants to float, place a small plate or a water-filled zip bag on top as a weight.

Cover the container and refrigerate for at least 12 hours and up to 24 hours. For best flavor and seasoning all the way through, aim for about 18–24 hours. If the pork is not fully covered, turn it over halfway through the brining time so every side gets equal exposure to the brine.

Step 4: Rinse, dry, and apply the rub (air-dry for best smoke)

When the brining time is up, remove the pork from the brine and discard the brine. Rinse the pork quickly but thoroughly under cold running water to remove excess surface salt, then pat it very dry with plenty of paper towels.

If you are sensitive to salt, you can briefly soak the pork in cold water for 10–15 minutes after brining, then pat dry. This step is optional but can lightly reduce saltiness.

In a small bowl, combine all the dry rub ingredients: brown sugar, paprika, black pepper, garlic powder, onion powder, dry mustard, and smoked paprika (if using). Mix well to break up any lumps.

If the surface of the pork feels very dry and the rub is not sticking, lightly coat the shoulder with 1–2 tablespoons of neutral oil. Sprinkle the rub evenly over all sides of the pork, pressing it on so it adheres but not packing it too thickly.

Place the rubbed pork on a wire rack set over a rimmed baking sheet and refrigerate it uncovered for at least 1 hour and up to 12 hours. This short air-dry helps form a tacky surface (a pellicle) that grabs smoke beautifully and leads to better texture and flavor.

Step 5: Set up the smoker and smoke low and slow

About 30–45 minutes before you are ready to cook, set up your smoker (or grill for indirect smoking) to 225°F (107°C). For a smoker, follow the manufacturer’s directions. For a charcoal grill, build a small fire on one side and place a drip pan with a bit of water on the other; the pork will sit over the pan, away from direct heat. For a gas grill, light only one side of the burners and keep the pork on the unlit side.

Add your smoking wood: 2–3 cups of soaked and drained wood chips or 4–6 chunks of apple, cherry, or maple wood. Mild fruit woods give a gentle, sweet smoke that suits a cold cut-style pork beautifully and will not overwhelm the meat.

Place the pork shoulder on the smoker grate, fat side up, over indirect heat. Insert a probe thermometer into the thickest part of the roast, avoiding any large seams of fat. Close the lid and smoke at 225°F (107°C) until the internal temperature reaches 180–185°F (82–85°C). This will usually take about 6–8 hours for a 4–5 lb (1.8–2.3 kg) shoulder, depending on your smoker and ambient temperature.

If your smoker tends to run dry or hot, you can place a shallow pan of water inside to stabilize the temperature and humidity. Add more wood as needed during the first 2–3 hours for good smoke flavor; after that, the meat will not absorb much more smoke, so you can simply maintain temperature.

Step 6: Rest, cool safely, and chill completely

Once the pork reaches 180–185°F (82–85°C) and feels tender when you insert the probe (it should offer some resistance but not feel tough), carefully remove it from the smoker to a clean tray or cutting board.

Tent loosely with foil and let it rest at room temperature for 20–30 minutes. This brief rest allows juices to redistribute and the surface to cool slightly, which helps prevent excessive moisture loss later.

After resting, remove the foil. Place the pork on a clean wire rack set over a rimmed baking sheet so air can circulate around it. Transfer to the refrigerator, uncovered, and chill until completely cold all the way through. This will take at least 4–6 hours; overnight (8–12 hours) is strongly recommended. Chilling uncovered initially helps the exterior firm up and lightly dry, which leads to very clean, thin slices.

Once fully cold and firm, you can wrap the roast tightly in plastic wrap or place it in an airtight container until you are ready to slice.

Step 7: Slice thin and serve as a cold cut

For best results, slice the pork when it is thoroughly chilled and firm. Use a long, sharp slicing knife or a meat slicer if you have one. Identify the direction of the grain (the lines of muscle fibers) and cut across the grain, not along it; this makes the slices wonderfully tender.

Aim for very thin slices, about 1–2 mm thick, just like deli meat. Arrange the slices on a platter or wooden board, slightly overlapping them. You can serve them plain or with accompaniments such as mustards, pickles, pickled onions, and crusty bread or crackers.

Serve the pork cold or lightly cool. It makes excellent charcuterie, sandwiches, sliders, and hearty salads. Keep any remaining unsliced roast well wrapped in the fridge, slicing only what you need so it stays moist as long as possible.

Pro Tips

• Use a scale for the brine salt. Because different brands of kosher salt measure differently by volume, weighing (150 g) ensures your brine is properly seasoned and not overly salty.
• Do not rush the chilling step. The pork needs to be completely cold to slice cleanly. If it is even slightly warm inside, it will tear and crumble instead of giving you neat, thin slices.
• Keep the smoker temperature steady. Aim for 225°F (107°C) and avoid frequent lid opening. Big temperature swings can lead to dry or unevenly cooked meat.
• Add smoke wood early, not constantly. Most of the smoke flavor is absorbed in the first 2–3 hours. After that, focus on maintaining temperature rather than piling on more wood.
• Slice against the grain. This is crucial for tender cold cuts. Take a moment to locate the grain direction before you start slicing.

Variations

• Garlic and herb version: Add 1 tsp dried thyme and 1 tsp dried oregano to the brine. Mix 1–2 tbsp finely minced fresh rosemary and thyme into the dry rub for a fragrant, savory profile.
• Smoky maple glaze: During the last 45 minutes of smoking, brush the pork once or twice with a mixture of 1/4 cup maple syrup and 1 tbsp apple cider vinegar. This gives a gentle sheen and a light sweet-smoky crust that works beautifully for sandwiches.
• Spicy chili-rubbed shoulder: Add 1–2 tsp chipotle chili powder or cayenne to the dry rub, and swap half the sweet paprika for smoked paprika. Use hickory wood for a bolder, more assertive smoke (still delicious chilled and sliced).

Storage & Make-Ahead

Because this smoked pork shoulder is designed as a cold cut, it is ideal for making ahead. Once the roast is fully chilled, wrap it tightly in plastic wrap and then in foil, or vacuum-seal if you have a sealer. Store in the refrigerator for up to 5–7 days.

For best texture and moisture, keep the roast whole and slice only what you need just before serving. Thinly sliced leftovers can be stored in an airtight container in the fridge for 3–4 days. To freeze, wrap the whole chilled roast very well (plastic wrap plus a freezer bag, or vacuum-sealed) and freeze for up to 3 months. Thaw overnight in the refrigerator before slicing.

If you want deli-style portions in the freezer, you can pre-slice the chilled roast, divide into small stacks (4–6 oz each), wrap tightly, and freeze flat in bags. Thaw in the fridge before using.

Nutrition (per serving)

Approximate values per 2 oz (60 g) serving of sliced smoked pork shoulder, without sauces or bread: about 130 calories, 8 g fat, 3 g saturated fat, 14 g protein, 1 g carbohydrates, 0 g fiber, 0 g sugar, and roughly 350–450 mg sodium (exact sodium will vary with brining time and brand of salt used).