Preparing the Ingredients

To start, gather all your ingredients and prep them for cooking. Dice your onions and peppers, open your cans of beans and tomatoes, and measure out your spices. For the meat, mix ground beef and sausage together in a large bowl, then form it into a meatball or loaf shape. This allows the meat to cook evenly on the smoker, infusing the chili with smoky drippings.

Smoking the Meat: Tips and Techniques

Set your smoker to 250°F and choose a wood chip that complements your flavors, such as hickory, mesquite, or applewood. Place your meatball or loaf on a wire rack above your chili pot, allowing the drippings to infuse the chili as it smokes. This step is crucial—it’s what gives smoked chili its signature flavor. Smoke the meat for about an hour or until the internal temperature reaches 150°F.

Layering Flavors in the Pot

While the meat is smoking, begin layering flavors in your chili pot. Combine diced onions, peppers, canned tomatoes, and your choice of beans with beef broth. Stir in your spices gradually, tasting as you go to achieve the perfect balance. Place the pot directly under the smoker rack to catch all the flavorful juices from the meat.

Cooking Times and Temperature Guidelines

After the meat reaches the desired temperature, break it into chunks and mix it into the chili pot. Turn up the smoker to 325°F and let the chili cook for another 30 minutes, stirring occasionally to ensure even cooking. The extra heat allows the flavors to meld together while the meat absorbs the smoky goodness.

Perfecting the Final Texture and Taste

Once your chili has simmered to perfection, remove it from the smoker and let it cool for about 10–15 minutes. This resting period helps the flavors settle and makes the dish easier to serve. Before plating, taste the chili and adjust the seasoning with salt, pepper, or a pinch of brown sugar if needed.