The Ultimate Smoked Chili Over The Top Recipe: Rich, Smoky Perfection (Serves 4)

Key Takeaways:

• Perfect blend of smoked meat and rich chili base creates unmatched depth
• 4-hour total cook time yields tender meat and developed flavors
• Beginner-friendly recipe with clear troubleshooting steps
• Freezer-friendly and great for meal prep

A Better Way to Make Chili

Ever made chili that just lacks that deep, rich flavor? Smoked chili over the top (OTT) solves this by smoking seasoned meat above the chili pot, letting those flavorful drippings enhance your base as it cooks.

Time Requirements

• Prep Time: 30 minutes
• Cook Time: 3.5 hours
• Total Time: 4 hours

Equipment Needed

• Pellet smoker or electric smoker
• Large cast iron pot or Dutch oven
• Wire rack or grill grate
• Meat thermometer
• Large mixing bowl
• Wooden spoon

Ingredients

For the Meat Layer:

• 2 lbs lean ground beef (80/20)
• 2 tablespoons chili powder
• 1 tablespoon smoked paprika
• 1 teaspoon black pepper
• 1 teaspoon salt

For the Chili Base:

• 2 onions, diced
• 3 cloves garlic, minced
• 2 cans (14.5 oz each) diced tomatoes
• 1 can (15 oz) kidney beans, drained
• 2 tablespoons tomato paste
• 2 cups beef broth
• 1 tablespoon Worcestershire sauce
• Optional: 1-2 diced jalapeños

Step-by-Step Instructions

Preparation Phase

1. Preheat your smoker to exactly 250°F. Wait until temperature stabilizes (about 15 minutes).
2. Combine meat seasonings in a small bowl:

• Measure each spice carefully
• Mix with a fork until evenly distributed
• Set aside

1. 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

1. 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

1. 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

1. Prepare your vegetables:

• Dice onions into 1/4 inch pieces
• Mince garlic very finely
• If using jalapeños, remove seeds and dice small

1. 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

1. 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)

1. Position cooking rack:

• Place wire rack securely over pot
• Test stability before adding meat
• Center rack over the pot

1. 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

1. Begin smoking:

• Close smoker lid completely
• Check temperature reads 250°F
• Don’t open lid for first hour

1. Monitor temperature:

• Check every 30 minutes
• Adjust smoker controls if needed
• Keep as close to 250°F as possible

1. First meat check (1.5 hours):

• Open lid briefly
• Break meat into 4-5 large chunks
• Use tongs, not fork
• Close lid quickly

1. Temperature check (2.5 hours):

• Insert meat thermometer into thickest part
• Look for 165°F minimum
• Check multiple spots

1. Combine ingredients:

• Once meat reaches 165°F, remove rack
• Break meat into small chunks
• Stir meat into chili base thoroughly
• Check seasoning levels

1. Final cooking phase:

• Continue cooking 30-60 minutes
• Stir every 15 minutes
• Look for desired thickness
• Chili should coat back of spoon

Troubleshooting

Too Thin:

• Add tomato paste
• Simmer uncovered
• Break up meat more finely

Too Thick:

• Add beef broth
• Stir regularly
• Reduce heat

Not Enough Smoke:

• Use stronger wood pellets
• Extend smoking time
• Lower cooking temperature

Storage & Reheating

• Refrigerate up to 5 days
• Freeze up to 3 months
• Reheat on stovetop or microwave
• Add broth when reheating if needed

Safety Notes

• Verify meat temperature reaches 165°F
• Keep smoker temperature steady
• Use heat-resistant gloves
• Never leave smoker unattended

Variations

• Sub ground beef with brisket
• Add dark chocolate for richness
• Use different bean varieties
• Incorporate diced peppers
• Try various wood pellet flavors

Remember: Let chili rest 15 minutes before serving to develop flavors fully.