"Over The Top" Texas-Style Smoked Chili Recipe

Ingredients

• 1 tablespoon Olive Oil (extra virgin)
• 1 large Onion (diced)
• 1 large Bell Pepper (any color, diced)
• 1 large Jalapeño (seeded and diced)
• 1 tablespoon Garlic Jalapeño Rub (store‑bought or homemade)
• 1 tablespoon Beef Rub (any classic BBQ beef rub)
• 1 tablespoon Worcestershire Sauce
• 3 pounds Ground Chuck (80% lean)
• 1 pound Mild Breakfast Sausage (remove casing if present)
• 2 tablespoons Ancho Chili Powder
• 1 teaspoon Cumin
• 28 ounce Diced Tomatoes (canned, no added salt)
• 1 can Rotel Diced Tomatoes & Green Chilies (original flavor)
• 15 ounce Tomato Sauce
• 6 ounce Tomato Paste
• 7 ounce Beef Broth (half of a 14‑oz can)
• 1 can Miller Lite Beer (12 oz, chilled)
• 1 cup Shredded Cheddar Cheese (for topping)
• 1 cup Shredded Monterey Jack Cheese (for topping)
• 0.25 large Additional Onion (diced, for garnish)
• 2 tablespoons Sour Cream (optional topping)
• to taste Salt
• to taste Black Pepper

Instructions

1. Preheat Grill

   Set the Traeger grill to 250‑275°F (about 260°F) and let it come to temperature.

   Time: PT15M

   Temperature: 260°F

2. Dice Vegetables

   Dice the onion, bell pepper, and jalapeño. Remove the seeds from the jalapeño for milder heat, if desired.

   Time: PT10M

3. Sauté Vegetables in Dutch Oven

   Place the Dutch oven on the grill grates (use a sheet of foil underneath to protect the pot). Add 1 tbsp olive oil, then add the diced onion, bell pepper, and jalapeño. Close the grill lid and let smoke‑sauté for about 1 hour, stirring once halfway through, until the vegetables are softened and lightly translucent.

   Time: PT1H

   Temperature: 260°F

4. Season Vegetables

   Sprinkle the garlic jalapeño rub, beef rub, and Worcestershire sauce over the vegetables. Stir to coat evenly.

   Time: PT5M

5. Prepare Meat Ball

   In a mixing bowl, combine ground chuck and mild breakfast sausage. Add a generous pinch of garlic jalapeño rub and beef rub, then mix until just combined. Form the mixture into a loosely packed ball (about 4‑5 lbs total).

   Time: PT15M

6. Smoke Meat Ball

   Place the meat ball on a cooling rack set directly above the Dutch oven so the drippings fall into the pot. Close the grill lid and smoke for 1 hour at 260°F.

   Time: PT1H

   Temperature: 260°F

7. Raise Temperature and Continue Smoking

   Increase the grill temperature to 325°F. Continue smoking the vegetables and meat ball for another hour (or up to 1½ h) until the meat’s internal temperature reaches about 130‑135°F.

   Time: PT1H

   Temperature: 325°F

8. Add Dry Spices

   Stir in 2 tbsp ancho chili powder and 1 tsp ground cumin into the pot. Mix well.

   Time: PT5M

9. Add Canned Liquids and Tomatoes

   Pour in the 28‑oz can of diced tomatoes, 1 can of Rotel, 15‑oz tomato sauce, 6‑oz tomato paste, 7 oz beef broth (half the can), and the whole 12‑oz Miller Lite beer. Stir to combine.

   Time: PT5M

10. Crumble Meat Ball into Chili

    Using heat‑resistant gloves and a spatula, remove the meat ball from the rack, break it up into bite‑size pieces, and stir it into the pot.

    Time: PT5M

11. Simmer and Finish

    Close the grill lid and let the chili simmer at 325°F for 1½ hours, stirring every 30 minutes. Taste and adjust seasoning with additional chili powder, cumin, salt, or pepper as needed.

    Time: PT1H30M

    Temperature: 325°F

12. Skim Excess Grease

    Lay a paper towel on a disposable plate and gently dab the surface of the chili to absorb excess grease.

    Time: PT5M

13. Serve

    Ladle the chili into bowls. Top each serving with shredded cheddar, shredded Monterey Jack, diced raw onion, and a dollop of sour cream if desired.

    Time: PT5M

Nutrition Facts

Calories

520

Protein

35 g

Carbohydrates

30 g

Fat

30 g

Fiber

5 g

Ingredient Substitutions

• Instead of Olive Oil: vegetable oil, canola oil
• Instead of Onion: shallot, yellow onion
• Instead of Bell Pepper: poblano pepper, red pepper
• Instead of Jalapeño: serrano pepper, chipotle in adobo (for smoky heat)
• Instead of Garlic Jalapeño Rub: garlic powder + cayenne, chipotle powder
• Instead of Beef Rub: steak seasoning, smoked paprika blend
• Instead of Worcestershire Sauce: soy sauce, fish sauce (use less)
• Instead of Ground Chuck: ground beef (85% lean), ground turkey (for lighter version)
• Instead of Mild Breakfast Sausage: Italian sausage (mild), ground pork
• Instead of Ancho Chili Powder: guajillo powder, regular chili powder
• Instead of Cumin: ground coriander, cumin seeds (to toast)
• Instead of Diced Tomatoes: fresh diced tomatoes, crushed tomatoes
• Instead of Rotel Diced Tomatoes & Green Chilies: diced tomatoes with jalapeños, homemade diced tomatoes + green chilies
• Instead of Tomato Sauce: crushed tomatoes, passata
• Instead of Tomato Paste: extra tomato puree, ketchup (in pinch)
• Instead of Beef Broth: chicken broth, water with bouillon
• Instead of Miller Lite Beer: any light lager, ale
• Instead of Shredded Cheddar Cheese: sharp cheddar, Mexican blend cheese
• Instead of Shredded Monterey Jack Cheese: Monterey Jack blend, Colby cheese
• Instead of Additional Onion: green onions, scallions
• Instead of Sour Cream: Greek yogurt, creme fraiche
• Instead of Salt: sea salt, kosher salt
• Instead of Black Pepper: white pepper, ground cayenne (use less)

Equipment Needed

• Traeger Pellet Grill
• Cast Iron Dutch Oven (Lodge)
• Aluminum Foil
• Mixing Bowl
• Chef's Knife
• Cutting Board
• Measuring Spoons
• Cooling Rack
• Heat‑Resistant Gloves
• Spatula
• Tongs (optional)
• Ladle (optional)
• Paper Towels (optional)

Critical Steps — Do Not Skip

• Preheating the grill to the correct temperature
• Smoking the meat ball over the vegetables
• Adding the dry spice blend before the liquids
• Crumbling the smoked meat ball into the pot
• Simmering the chili long enough for flavors to meld
• Skimming excess grease for a balanced texture

Chef Tips from the Video

• Use Royal Oak charcoal pellets for a classic Texas smoke profile.
• Let the meat ball rest for a few minutes after smoking before crumbling; it holds its juices better.
• For extra depth, add a splash of bourbon or coffee along with the beer.

Troubleshooting

Storage

Refrigerator: Cool to room temperature, then store in airtight containers for up to 4 days.

Freezer: Freeze in freezer‑safe containers for up to 3 months. Thaw overnight in the fridge before reheating.

Room temperature: Do not store at room temperature for more than 2 hours.

Make-Ahead Tips

• The chili improves in flavor after a night in the refrigerator; reheat gently on the stove or back on the grill.
• Freeze individual portions for quick meals; thaw and reheat on low heat to prevent scorching.

Frequently Asked Questions