Grilled Boston Butt Pork Roast: A Step-by-Step Guide

Grilling a boneless Boston butt pork roast may sound intimidating, but it’s actually one of the easiest and most flavorful pork dishes you can make. This cut becomes fall-apart tender and juicy with indirect heat and just a simple dry rub.

In this complete guide, I’ll walk you through every step of cooking boston butt on the grill from start to finish. You’ll learn how to choose the right size roast, prep and season it, control grill heat, and get perfect doneness. Let’s fire up the grill!

Picking the Best Boston Butt for Grilling

The first key to success is choosing the right cut of pork, Here’s what to look for

• Boneless Boston butt/pork shoulder: Uniform shape allows even cooking.

• 4-6 pounds Provides plenty of meat without being unwieldy

• Some marbling: Fat keeps it moist and adds flavor. Avoid very lean roasts.

• Untreated, unenhanced meat Fresh pork absorbs seasoning best

• Moderate price: Costs just $1.50-$2.50 per pound.

With the ideal roast selected, it’s time to prep for grilling.

Prepping Pork Butt for the Grill

Proper prep ensures great flavor and texture:

• Pat roast dry and let sit out for 30 minutes to remove chill.

• Coat all over with olive oil to prevent sticking.

• Generously apply rub. Get into crevices and underside.

• Refrigerate 2+ hours so spice flavors penetrate meat.

• Let roast sit out for 30 minutes before grilling to take off chill.

I love using a sweet and smoky pork rub. A homemade blend of brown sugar, paprika, garlic, salt, and pepper is perfect.

Setting Up Your Grill

Controlling temperature is key for tender, juicy results:

• Use indirect heat with no coals/flame under meat.

• Place roast in center of grate over drip pan.

• Maintain grill at 275°F-300°F. Use an oven thermometer to check.

• Close lid for convection cooking. Don’t peek!

• Add soaked wood chips for extra smoke flavor if desired.

• Rotate roast 180 degrees halfway through for even cooking.

This low, slow grill method gently breaks down collagen for succulent pork.

Estimated Grill Times

Cooking time varies by size. Estimate:

• 4 lb roast: 3-4 hours
• 5 lb roast: 4-5 hours
• 6 lb roast: 5-6 hours

Use a meat thermometer to check doneness instead of relying solely on time.

Checking for Proper Doneness

When finished, the pork should register:

• 195°F-205°F for well-done, pullable meat

• 170°F-185°F for slicing into juicy medallions

The collagen breakdown that produces tender, shreddable meat happens between 195°-205°F. Let rest 10-20 minutes before checking temp.

Making Delicious Pulled Pork

For easy pulled pork:

• Carefully transfer roast to a rimmed baking sheet.

• Tent loosely with foil and let rest for 20-30 minutes.

• Use bear claws or 2 forks to shred, discarding excess fat.

• Toss with barbecue sauce or rub juices to coat.

You can also slice into slices or medallions for sandwiches or dinner entrees.

Serving Your Tasty Boston Butt

Try these fantastic ways to serve your grilled pork:

• On buns for pulled pork sandwiches with coleslaw

• Chopped in baked beans or chili

• Diced in mac and cheese or nachos

• Over roasted veggies and mashed potatoes

• In tacos, burritos, quesadillas, and more

Leftovers will keep refrigerated for up to 5 days. Reheat in the microwave or oven.

Tips for Grilling the Perfect Pork Roast

For flawless Boston butt pork roast, remember:

• Apply rub generously over entire roast.

• Use indirect heat and refrain from peeking.

• Go by temp, not time. Cook to 195°-205°F.

• Let rest 20-30 minutes before pulling or slicing.

• Save defatted drippings for homemade barbecue sauce.