Key Takeaways:
- Smoky drippings create unmatched flavor depth in this Smoked Chili Over The Top recipe
- Perfect for entertaining with minimal hands-on time (only 30 minutes prep)
- Simple technique that even beginners can master
- Makes exactly 4 generous portions (freezes beautifully for later)
Why Your Chili Needs The Over-The-Top Treatment
Regular chili just doesn’t compare to Smoked Chili Over The Top. I discovered this game-changing technique last fall and haven’t looked back. The magic happens when seasoned meat smokes directly above your simmering chili pot, allowing those flavorful drippings to slowly enhance the base below. This Smoked Chili Over The Top recipe transforms an ordinary dish into something extraordinary without complicated techniques.
Want to kick your chili up even more? Try pairing it with my homemade sweet chili sauce for an incredible flavor combination.
Time Requirements
- Prep Time: 30 minutes
- Cook Time: 3.5 hours
- Total Time: 4 hours
- Serves: 4 people
Nutrition Information (Per Serving)
| Nutrient | Amount |
|---|---|
| Calories | 420 |
| Protein | 35g |
| Carbohydrates | 26g |
| Fat | 19g |
| Fiber | 8g |
| Sodium | 650mg |
Equipment Needed
| Equipment | Purpose |
|---|---|
| Pellet smoker or electric smoker | Main cooking device |
| Large cast iron pot or Dutch oven (5-6 quart) | Holds chili base |
| Wire rack or grill grate | Supports meat above pot |
| Meat thermometer | Ensures food safety |
| Large mixing bowl | For meat preparation |
| Wooden spoon | For stirring |
Ingredients
For the Meat Layer:
| Ingredient | Amount |
|---|---|
| Lean ground beef (80/20) | 2 pounds |
| Chili powder | 2 tablespoons |
| Smoked paprika | 1 tablespoon |
| Black pepper | 1 teaspoon |
| Salt | 1 teaspoon |
For the Chili Base:
| Ingredient | Amount |
|---|---|
| Onions, diced | 2 medium |
| Garlic, minced | 3 cloves |
| Diced tomatoes | 2 cans (14.5 oz each) |
| Kidney beans, drained | 1 can (15 oz) |
| Tomato paste | 2 tablespoons |
| Beef broth | 2 cups |
| Worcestershire sauce | 1 tablespoon |
| Jalapeños, diced (optional) | 1-2 |
Substitution Options:
- Ground turkey instead of beef (reduce smoke time by 30 minutes)
- Black beans instead of kidney beans
- Chicken broth instead of beef broth (for a lighter flavor)
- Coconut aminos instead of Worcestershire sauce (gluten-free option)
Preparation Phase
- Preheat your smoker to exactly 250°F. Wait until temperature stabilizes (about 15 minutes).
- Combine meat seasonings in a small bowl:
- Measure each spice carefully
- Mix with a fork until evenly distributed
- Set aside
- Season the ground beef:
- Place meat in large mixing bowl
- Sprinkle seasoning mix evenly over meat
- Gently mix with hands until just combined
- Don’t overwork the meat
- Shape the meat mixture:
- Form into one large, loose ball
- Aim for 6-8 inches wide
- Keep it somewhat loose for better smoke penetration
- Place on a plate temporarily
- Prepare your cooking setup:
- Place cast iron pot in center of smoker
- Ensure 3-4 inches clearance above pot
- Check pot is level and stable
Chili Base Assembly
- Prepare your vegetables:
- Dice onions into 1/4 inch pieces
- Mince garlic very finely
- If using jalapeños, remove seeds and dice small
- Layer base ingredients in this order:
- Pour beef broth in first
- Add diced onions and garlic
- Pour in diced tomatoes with juice
- Add drained beans
- Stir in tomato paste
- Add Worcestershire sauce last
- Mix the base:
- Use wooden spoon to combine thoroughly
- Scrape bottom to ensure nothing sticks
- Check liquid level (should cover ingredients by 1/2 inch)
- Position cooking rack:
- Place wire rack securely over pot
- Test stability before adding meat
- Center rack over the pot
- Position meat:
- Carefully transfer meat ball to center of rack
- Ensure it’s directly over the pot
- Check that drippings will fall into chili
Smoking Process
- Begin smoking:
- Close smoker lid completely
- Check temperature reads 250°F
- Don’t open lid for first hour
- Monitor temperature:
- Check every 30 minutes
- Adjust smoker controls if needed
- Keep as close to 250°F as possible
- First meat check (1.5 hours):
- Open lid briefly
- Break meat into 4-5 large chunks
- Use tongs, not fork
- Close lid quickly
- Temperature check (2.5 hours):
- Insert meat thermometer into thickest part
- Look for 165°F minimum
- Check multiple spots
- Combine ingredients:
- Once meat reaches 165°F, remove rack
- Break meat into small chunks
- Stir meat into chili base thoroughly
- Check seasoning levels
- Final cooking phase:
- Continue cooking 30-60 minutes
- Stir every 15 minutes
- Look for desired thickness
- Chili should coat back of spoon
Troubleshooting Guide
| Problem | Solution |
|---|---|
| Chili Too Thin | • Add 1-2 tablespoons tomato paste<br>• Simmer uncovered for 20-30 minutes<br>• Break up meat into smaller pieces to release more binding proteins |
| Chili Too Thick | • Add beef broth ¼ cup at a time<br>• Stir every 5 minutes to prevent scorching<br>• Reduce heat to maintain gentle simmer |
| Not Enough Smoke Flavor | • Try hickory or mesquite wood pellets<br>• Extend smoking time by 30 minutes<br>• Lower cooking temperature to 225°F for slower cooking |
| Meat Drying Out | • Use meat with higher fat content (70/30)<br>• Check temperature more frequently<br>• Remove meat from heat once it reaches 165°F |
Variations & Substitutions
Looking to change things up? Try these spin-offs of the classic Smoked Chili Over The Top recipe:
- Spicy Southwest Version
- Add 1 tablespoon of ground cumin
- Mix in 1 can of fire-roasted green chilies
- Top with avocado and lime wedges
- Hearty Winter Version
- Substitute 2 lbs of cubed chuck roast for ground beef
- Add 1 cup of chopped carrots to the base
- Stir in 1 cup of corn kernels during the final hour
- Mediterranean Twist
- Use ground lamb instead of beef
- Add 1 teaspoon each of cinnamon and coriander
- Finish with fresh mint and a dollop of Greek yogurt
For another flavorful chili variation, check out my Chili Verde Pork recipe – it’s a completely different flavor profile but equally delicious!
Storage & Reheating Instructions
This Smoked Chili Over The Top recipe actually tastes even better the next day! Here’s how to store and reheat properly:
- Refrigeration: Store in airtight container up to 5 days
- Freezing: Portion into freezer-safe containers and freeze up to 3 months
- Stovetop Reheating: Warm over medium-low heat with ¼ cup added broth
- Microwave Reheating: Heat in 1-minute intervals, stirring between each
- Slow Cooker: Reheat on low for 2-3 hours, perfect for entertaining
Pro Tip: If freezing, cool completely before transferring to containers.
Safety Notes & Tips
- Temperature Safety: Always verify ground beef reaches 165°F minimum
- Equipment Handling: Use heat-resistant gloves when handling hot pots
- Fire Safety: Never leave smoker unattended during cooking
- Prep Warning: Wash hands after handling raw meat before touching other ingredients
- Dietary Notes: This recipe contains gluten (in Worcestershire sauce) – use gluten-free alternative if needed
Looking for a great appetizer while your chili smokes? Try my Spicy Chili Lime Roasted Pumpkin Seeds for a perfect snack to tide everyone over.
Final Tip: Let your Smoked Chili Over The Top rest for 15 minutes before serving. This allows flavors to meld and helps thicken the consistency.
