Mustard-Grilled Chuck Roast

It’s been a while since we warmed up the grill for a nice beef roast…so what better day than this past weekend to do so.  The only real prep is making sure the roast is fully thawed out before cooking – which means simply pulling it out of the freezer the night before when you go to bed and leaving it on the counter overnight.  As long as your house isn’t 85 degrees inside (I won’t say any names here), you should wake up to a fully thawed but still cool roast to start working with.  And since most chuck roasts fall closer to the size of a “large, thick steak” the cooking time is not so long you couldn’t manage cooking this on an average week night either.

Gather Up:

  • ~3-1/2 pound grassfed chuck roast (we’ve got a 7-bone roast today)
  • 1 tbsp generic yellow mustard (all natural – most are actually)
  • 1 tbsp Frank’s Red Hot or other red pepper/cayenne sauce
  • 1 tbsp Worcestershire sauce (get the HFCS-free stuff)
  • 1 tsp garlic powder
  • 1 tsp coarse black pepper

Assuming you’ve followed the directions up top and have already thawed the roast out overnight, it’s time to get things “soaking.”  Mix the marinade paste ingredients together in a small prep bowl and then spread evenly all over the roast – making sure to get the sides as well.  I put a large piece of plastic wrap on the counter, then covered one side and placed that side down on the plastic before continuing to cover everything else.  Finally, wrap the coated roast tightly in that same plastic wrap (I’d also put a second layer on for good measure) and place in the fridge.  Leave it alone for at least 4 hours (if you complete this step in the morning right after breakfast, you can head to work and everything will be ready to cook when you get home).

Roughly 30 to 45 minutes before you start to cook, you want to pull the wrapped roast out of the refrigerator to get it up to room temperature.  Throwing cold meat onto a hot surface to cook increases your chances of overcooking the outside and undercooking the inside (you’ve got longer to get the inside up to temperature, while the outside is in contact with high heat longer).  When the roast is near room temperature, start warming the grill up to a smoking temperature of around 180 degrees.

My preference, since I have a pellet grill, is to smoke for about 20~30 minutes and then raise the temperature up to my cooking temperature until the roast reaches the right internal reading.  If you’re not set up to do this easily, you can skip the smoking step and proceed directly to the cooking – but note that your overall cooking time will vary more than slightly from mine.

After about 20 minutes of smoking at 180 degrees, stab a meat thermometer into the roast from the side, so that it is reading the middle of the thickness and close (but not touching) the bone.  Raise the temperature of the grill to 400 degrees indirect heat and continue cooking until the thermometer reads 135 degrees (for medium rare).  I set a timer to check after 30 minutes, assessed the temperature at that time, and then rechecked in 10 minutes, and one more time at 5 minutes longer (that’s 45 minutes total after raising the temperature).

Remove from the grill and place on a large plate or cutting board and cover tightly with foil.  Let sit for about 10 minutes while you finish getting any side dishes ready to serve.  After the roast has rested, cut across the grain into ~1/4″ slices and serve warm.  Dig in!


5 responses to “Mustard-Grilled Chuck Roast

  1. This was delicious! We will make this recipe again. The beef was so tender and so flavorful!

  2. You know the USDA considers that to be an unsafe way of defrosting meat. Bacteria multiply in any temperature over 40 degrees.

    This recipe looks good, but I’ll defrost my meat in the fridge 🙂

  3. Point taken. With approx 8 hours on the counter fully wrapped in the double freezer paper and plastic from the butcher, I find that a 3-1/2 lb roast is just thawed and still reads about 36 degrees in the middle using my thermo pen, versus almost 2 days in the fridge. Given that the outside surface where any potential “activity” is going on is also the area that will be hitting the hot grill and exposed to higher temperatures longest, it has never been a problem for us (but I’m not saying the potential isn’t there…). Also sticking with non-feedlot animals processed in small facilities with better quality control goes a long way in reducing the potentials for exposure to problems in the meat to start with.

  4. I thaw my meat this way daily, granted we do raise our own cattle and hogs, but we have never had a problem.

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