Does butterflying a pork butt really produce more bark?

Yes, significantly more. A whole pork butt has most of its mass interior to the smoke, with bark only forming on the outer surface. Butterflying opens the meat flat so nearly the entire surface is exposed to airflow and smoke for the full first phase of the cook. The result is bark throughout every bite of the final pulled pork, not just the outer pieces.

How long does it take to smoke a butterflied pork butt?

Plan for 6–7 hours of active cook time. The flat smoke phase at 265°F takes roughly 5 hours to build bark and reach 165–175°F internal temp. The foil-wrapped finish at 300°F takes another 1.5–2.5 hours to reach probe-tender at 203–208°F. Add a 45-minute rest before shredding. Total elapsed time from fire-up to table is typically 7.5–8.5 hours, compared to 10–14 for a whole butt.

What temperature do you smoke a butterflied pork butt at?

Two temperatures. Start at 265°F for the open flat phase where bark builds, then bump to 300°F after wrapping in foil to push through to probe-tender faster. The lower temp during the bark-building phase gives smoke more time to work and keeps the outer surfaces from overcooking before the interior catches up. Once the foil goes on, the higher temp is fine because the moisture is trapped and you're just finishing the collagen.

Can I use a bone-in pork butt for this method?

Yes, but you'll need to remove the bone first. Use a sharp boning knife and follow the bone around its circumference until it pulls free, then proceed the same way you would with a boneless butt. The seams left by the bone will actually guide your butterfly cut nicely. It's extra work, but bone-in butts can have great flavor from the bone during the initial smoke phase if that's what you're working with.

What internal temp should a butterflied pork butt be when I wrap it?

Wrap when the bark is set and firm, which typically lands between 165–175°F. Don't use temperature alone as your trigger. Use the bark test: press the surface with a finger. If it springs back and feels dry and firm, it's ready. If it indents or still feels tacky, give it more time unwrapped even if the temp is in range. The bark won't improve after the foil goes on.

How do I keep butterflied pulled pork from drying out?

Three things: don't push past probe-tender, rest it in the foil for a full 45 minutes before opening, and pour the foil juices back over the meat as you shred. A butterflied butt has more exposed surface than a whole butt, which is exactly what makes it great for bark. That same exposure means you want to be attentive at the wrap stage and not extend the cook longer than needed.

Is a butterflied pork butt the same as a pork shoulder roast?

They come from the same primal cut. "Pork butt" and "pork shoulder" get used interchangeably at the grocery store, but technically the butt is the upper portion and the shoulder (picnic) is the lower. For this recipe, you want the upper butt portion. It has more even fat distribution and the muscle seams open more cleanly for butterflying. A picnic shoulder has more connective tissue and a shape that's harder to open flat.

Smoked Butterflied Pork Butt (More Bark, Better Pulled Pork)

Ingredients

Scale

1 boneless pork butt (pork shoulder), 6–9 lbs
Your rub of choice, approximately 2 tablespoons per pound

Cook Mode Prevent your screen from going dark

Instructions

Butterfly the pork butt by following the natural muscle seams with a sharp knife, opening it flat to no more than 3 inches thick at the deepest point.
Apply rub generously to all surfaces — top, bottom, and along the seams. Press in to adhere. Rest at room temperature for 20–30 minutes, or refrigerate overnight.
Preheat smoker to 265°F.
Place the butterflied butt fat-side up, fully open and flat on the grates. Smoke at 265°F for approximately 5 hours until bark is dark, firm, and dry, and internal temperature reads 165–175°F.
Remove from smoker. Fold the butt back in on itself and double-wrap tightly in heavy duty aluminum foil.
Return to smoker or oven at 300°F. If finishing in the oven, place on a baking sheet to catch drips. Cook until probe-tender at 203–208°F, approximately 1.5–2.5 hours more.
Rest wrapped for 45 minutes. Open foil, pour juices back over meat, and shred. Mix bark pieces throughout.

Notes

Make-ahead: Season and butterfly the night before. Refrigerate uncovered for up to 12 hours. The overnight rest improves bark formation.
Storage: Refrigerate pulled pork with juices for up to 4 days. Reheat covered on low with a splash of apple juice or water. Freezes well for 3 months.
Substitutions: Bone-in pork butt works — remove the bone before butterflying. A picnic shoulder can be used but is harder to open flat.
Oven finish: Once wrapped in foil, you can finish at 300°F in the oven instead of the smoker. Place on a baking sheet to catch any drips.

Author: Brad Prose
Prep Time: 20 minutes
Rest Time: 45 minutes
Cook Time: 6-7 hours
Category: Pork
Method: smoking
Cuisine: American BBQ, BBQ
Diet: Gluten-Free

Nutrition

Serving Size:
Calories: 288
Sugar: 0.4 g
Sodium: 620.3 mg
Fat: 12.1 g
Carbohydrates: 2.4 g
Protein: 41.6 g
Cholesterol: 133.7 mg