It had been a while since I tackled an overnight smoke, and the freezer had officially run dry of my go-to stash of pulled pork. So when I saw a good deal on Boston Butts—six of them—I knew it was time to fire up the smoker. After checking the weekend forecast and seeing Saturday night looked perfect, I got to work.

I gave each pork butt a basic trim, just enough to clean up any excess fat, then moved on to seasoning. My prep style is pretty straightforward: I like to season the meat about an hour or two before it hits the smoker. I start with a light dusting of salt and black pepper, then go in heavy with garlic powder and paprika. For a little twist, I add turbinado sugar (also known as sugar in the raw), which brings a subtle sweetness and helps build a beautiful bark during the cook.

I make sure to season every side thoroughly—even if the pictures don’t quite show it, nothing gets left behind.

For this cook, I used my trusty 22″ Weber Smokey Mountain. It’s the perfect size for handling all six pork butts with room to spare. I’ve been running this smoker for over 20 years, and it’s never let me down.

Fuel-wise, I stick with what works: Kingsford Blue Bag (KBB). It’s been my go-to charcoal since day one. The smoker runs primarily on charcoal, and for long overnight smokes like this, I almost completely fill the bottom chamber with unlit briquettes. I bury 3–4 fist-sized chunks of hickory wood throughout the charcoal bed—just enough to give the meat that deep, smoky flavor without overdoing it.

To get things started, I light a full chimney of charcoal. I’ve always used my old propane grill as a safe, elevated platform for this step. Years ago, I read about someone setting a lit chimney directly on concrete and having it explode from the heat. That stuck with me. Better safe than sorry.

Once the charcoal is lit it is then dumped onto of the unlit charcoal in the bottom chamber.

Getting It Rolling: Water Pan, Probes & Pork

With the charcoal glowing and the base hot, I assembled the smoker by adding the middle section, which includes the water pan. I filled the pan with about 3 gallons of water. In the Weber Smokey Mountain, the water serves two purposes: it acts as a heat sink to maintain a steady temperature, and it adds a bit of humidity to the cook chamber, which helps keep the bark from drying out too quickly.

Once the pan was filled, I loaded three of the pork butts onto the bottom rack. I connected two of the four probes from my wireless thermometer setup—one inserted into a pork butt and the other placed on the rack to monitor ambient temperature. After that, I installed the top grate and added the remaining three butts, along with the final two probes.

The smoker was fully loaded and ready to roll just after 8 p.m.

To give the meat an early hit of smoke, I tossed a few chunks of hickory wood directly onto the hot coals. The remaining chunks, buried deep in the charcoal bed during prep, would kick in gradually as the fire burned down—ensuring a long, slow infusion of flavor throughout the night.

Set It and Trust It: Vents, Temps & the Stall

After years of using this smoker, I’ve learned to trust the process. The Weber Smokey Mountain has four vents: one on the top and three at the bottom. The top vent stays 100% open for the entire cook—it allows smoke and excess heat to escape properly. The real control comes from the bottom vents.

When I first start the cook, I close two of the three bottom vents completely and leave the third one about 50% open. That setup provides just the right amount of airflow for the smoker to gradually climb to around 225°F—and then sit there steady for 8 to 10 hours without any need to touch it.

Once I saw on my phone that the temps had settled in, I headed to bed without giving it another thought. The smoker was in its zone.

I checked in again around 5 a.m. Everything was running smooth, but the internal temps of the pork were hovering around 160°F—right on cue for the stall. That’s when I started the spritzing process.

Over the years, I’ve tried a few different spritz options, but I’ve landed on one that works really well: purple grape juice. It’s got a high sugar content, which helps build a nice bark and adds a rich color to the finished pork. Plus, it smells amazing when it hits the meat.

Midday Adjustments: Golf, the Stall, and More Charcoal

After checking on the temps that morning, I headed out to play a round of golf—18 holes. By the time I got back, the pork butts had only crept up to about 175°F. The stall was hanging on strong.

At that point, I noticed I was also running low on charcoal. Time to refuel. I fired up another chimney full of KBB. While it was getting ready, I carefully removed the three butts from the top grate and took off the top rack. Then I pulled the bottom three butts out to make room.

With the grates clear, I added more unlit charcoal to the chamber, followed by the fully lit chimney of hot coals. I reassembled the smoker but decided not to refill the water pan this time around. The bark was already well underway, and I didn’t want to soften it too much with added moisture.

Once the smoker was back together, I returned the three butts to the bottom grate, then placed the other three back on top. I gave everything a generous spritz of grape juice and let the smoke session continue.

The Finish Line: Patience, Probing, and the Rest

Over the next several hours, I continued spritzing the butts roughly once an hour, keeping the bark moist and letting that grape juice do its thing. I watched the temps slowly climb, aiming for around 195°F—a number I’ve come to trust over the years.

That said, it’s not a strict rule. Every cut of meat is different. I also go by feel. When you probe the pork and the thermometer slides in with little to no resistance—like softened butter—you know it’s ready. That tactile feedback is just as important as the number on the screen.

Once the butts hit the sweet spot, I pulled them off the smoker and wrapped each one tightly in foil. From there, they went into a cooler lined with towels to rest. This resting period is critical—it allows the juices to redistribute and the meat to relax.

Even though the internal temperature will drop slightly during the rest, it will stay above 160°F for six hours or more. That gives you a long holding window without sacrificing quality, which is especially useful when you’re managing multiple cuts or timing a big meal.

Dinner Time: The Payoff

One of the butts was pulled and served fresh for dinner—and let me tell you, the aroma alone was worth the all-night cook. It’s hard to describe just how good it smells when that perfectly smoked pork hits the table. The deep hickory scent, the sweet notes from the grape juice spritz, and the rich, seasoned bark all come together in a way that’s unforgettable.

As for the taste? Absolutely phenomenal. Tender, juicy, and packed with flavor from edge to center. Whether piled onto a bun, plated with sides, or just picked at straight from the tray, this pork never disappoints.

For our small family, we enjoyed about a pound of the pulled pork for dinner that night, and I bagged another pound to savor later in the week. Of the remaining five butts, one was sold, another gifted to friends, and three were pulled for future meals. The last one I refrigerated whole to slice the next day.

Slicing cold smoked pork butt is a great way to enjoy it—much like brisket—with beautiful, tender slices that hold their shape and flavor. It makes for a fantastic change of pace and stretches the deliciousness even further.

This yielded another 4 lbs of pulled pork that went into the freezer.

Ultimately, I was able to portion and freeze about 17 pounds of smoked pork from this cook. I’ve been doing it this way for years, and it really works.

When it’s time to enjoy, I reheat the pork by boiling the sealed bags in water. This method locks in all the flavor and aroma, so the meat tastes just as incredible as the moment it came off the smoker—fresh, juicy, and perfectly smoky every time.

Smoking pork butt low and slow is a labor of love, but the results are absolutely worth it. Using a trusted 22″ Weber Smokey Mountain, Kingsford Blue Bag charcoal, and just a few chunks of hickory wood, I was able to smoke six Boston butts overnight with minimal fuss. The water pan keeps the environment steady and moist, while carefully managing the vents lets the smoker hold a perfect 225°F for hours on end.

Spritzing with purple grape juice every hour during the stall helped develop a rich, flavorful bark with a beautiful color. Whether probing for the right tenderness or watching the internal temp climb to around 195°F, patience and experience guide the way.

Once off the smoker, wrapping the meat and letting it rest in a cooler allows the juices to redistribute, making for tender, juicy pulled pork that tastes incredible fresh or reheated.

From dinner plates to freezing 17 pounds for later meals, this method has been my go-to for years—and it’s a proven winner every time.

Ready to fire up your smoker and try this slow-smoked hickory pork butt for yourself? Grab your favorite wood, trust the process, and get ready for some mouthwatering results. Don’t forget to share your smoking stories and tips in the comments—I’d love to hear how your pitmaster journey goes!