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–+ servings
Seasoned ground chuck and Italian sausage loaf prepared for Smoked Over the Top Chili

Smoked Over the Top Chili

James Brown
Ground chuck and medium Italian sausage are smoked over a Dutch oven filled with peppers, fire—roasted tomatoes, beans, and spices, then broken apart and stirred into the chili to finish.
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Servings 10 servings
Calories 608 kcal
Print Recipe Pin Recipe
Prep Time 25 minutes
Cook Time 3 hours 30 minutes
Resting Time 15 minutes
Total Time 4 hours 10 minutes

Equipment

  • Smoker
  • Large Dutch Oven
  • Wire Rack
  • Large Mixing Bowl

Ingredients
  

For the Beef & Sausage Loaf

  • 2 lbs ground chuck
  • 1 lb medium Italian sausage
  • 3 tbsp BBQ seasoning plus more for seasoning the outside

For the Chili Base

  • 1 tbsp avocado oil
  • 1 yellow onion diced
  • 1 poblano pepper seeded and diced
  • 1 red bell pepper seeded and diced
  • 1 jalapeño diced
  • 5 cloves garlic minced
  • 3 tbsp tomato paste
  • 1 tbsp Worcestershire sauce
  • 1 tbsp adobo sauce
  • 2 tbsp chili powder
  • 1 tbsp ancho chili powder
  • 2 tsp ground cumin
  • 1 tsp dried oregano
  • 1 tsp smoked paprika
  • 28 oz fire-roasted crushed tomatoes
  • 14.5 oz fire-roasted diced tomatoes
  • 15 oz dark red kidney beans drained and rinsed
  • 15 oz pinto beans drained and rinsed
  • 1 1/2 cups beef stock

For Finishing & Serving

  • 1/2 oz dark chocolate
  • 2 tsp fresh lime juice
  • kosher salt to taste
  • 4 oz shredded cheddar cheese optional
  • 1/2 white onion diced, optional
  • 1/2 cup chopped cilantro optional
  • 2 sliced jalapeños optional
  • 6 oz sour cream optional
  • 1/2 cup corn chips optional

Instructions
 

  • Preheat the Smoker: Preheat the smoker to 275°F. Oak or pecan works well for this recipe.
  • Sauté the Vegetables: Heat the avocado oil in a large Dutch oven over medium heat. Add the yellow onion, jalapeño, red bell pepper, and poblano. Cook for 5—7 minutes, stirring occasionally, until softened. Add the garlic and cook for another 30 seconds.
  • Build the Chili Base: Add the tomato paste, Worcestershire sauce, and adobo sauce. Cook for 2—3 minutes, stirring frequently. Add the chili powder, ancho chile powder, cumin, oregano, and smoked paprika. Cook for about 30 seconds, stirring, before adding the tomatoes. Stir in the crushed tomatoes, fire-roasted diced tomatoes, dark red kidney beans, pinto beans, and beef stock. Scrape the bottom of the Dutch oven as you stir to work the concentrated bits into the chili.
  • Form the Meat Loaf: Add the ground chuck and medium Italian sausage to a large bowl with about 3 tablespoons of BBQ seasoning. Mix gently just until combined. Form the mixture into a wide, round loaf, then season the outside with an additional coating of BBQ seasoning.
  • Smoke Over the Chili: Place a wire rack across the top of the Dutch oven and set the seasoned meat loaf directly above the chili. Insert a temperature probe into the thickest part of the meat. Transfer everything to the smoker and cook uncovered at 275°F until the center reaches 160°F. I begin probing around 2 1/2 hours into the cook. Mine took 2 hours 45 mins; use internal temperature to determine when it's ready.
  • Break Apart the Meat: Remove the cooked loaf and transfer it to a large bowl or pan. Break it apart with utensils, leaving a mixture of smaller crumbles and larger pieces rather than chopping everything finely.
  • Finish the Chili: Add the smoked meat to the Dutch oven and stir until evenly distributed. Return the chili to the smoker uncovered at 275°F for about 40 minutes, stirring occasionally, until it reaches your preferred consistency.
  • Add the Chocolate and Lime: Remove the Dutch oven from the smoker. Stir in the dark chocolate until completely melted, then add the fresh lime juice. Taste and adjust the salt if needed.
  • Rest and Serve: Let the chili rest for 10—15 minutes. Spoon into bowls and serve with freshly shredded cheddar, diced white onion, cilantro, sliced jalapeños, sour cream, or corn chips.

Notes

  • Use 80/20 ground chuck with medium Italian sausage for the meat mixture.
  • Mix the meat gently; overworking it can make the finished pieces dense.
  • Form a wide, round loaf to expose more surface area during cooking.
  • Cook the meat to 160°F internal temperature before breaking apart.
  • Add the dark chocolate and lime at the end, after the chili comes off the smoker. 

Nutrition

Calories: 608kcalCarbohydrates: 39gProtein: 34gFat: 36gSaturated Fat: 13gPolyunsaturated Fat: 3gMonounsaturated Fat: 16gTrans Fat: 1gCholesterol: 99mgSodium: 1070mgPotassium: 1255mgFiber: 11gSugar: 8gVitamin A: 1792IUVitamin C: 38mgCalcium: 172mgIron: 9mg
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