BBQ Bacon Recipe Smoker: Double-Smoked Meaty Masterpiece

There’s a reason pitmasters swear by double-smoked bacon—it elevates the flavor to an entirely new level. This method transforms ordinary bacon into a meaty masterpiece with deep, smoky complexity that store-bought can’t touch.

By cold-smoking the bacon first, then finishing it on the smoker at 225°F, you create layers of flavor that build with each bite. The low, slow heat ensures the fat renders perfectly while infusing every strip with rich, wood-fired aroma.

The result is bacon that’s tender yet crisp, with a bark-like exterior and a smoky depth that lingers. It’s not just breakfast—it’s an experience that redefines what bacon can be.

Whether you’re feeding a crowd or treating yourself, this technique delivers professional-quality results every time. The smoker does most of the work.

Ingredients for Bbq Bacon Recipe Smoker

Thick-cut pork belly plus a handful of pantry staples transform into something extraordinary.

The pork belly is non-negotiable. Source from a reputable butcher—look for thick, evenly marbled slabs with skin on (you’ll remove it yourself). Whole Foods or local smokehouses often carry quality cuts. Avoid pre-sliced bacon; the thickness ensures it holds up to double-smoking. For the wood chips, hickory provides classic BBQ flavor, but apple or cherry wood adds a sweeter note (worth experimenting).

No pork belly? Thick-cut bacon from the butcher works in a pinch—just skip the initial cure. Out of brown sugar? Substitute with equal parts white sugar plus 1 tsp molasses. Swap maple syrup for honey if preferred (though maple’s depth is ideal). For the vinegar, white vinegar or even lemon juice can stand in, but cider vinegar’s fruitiness complements the smoke best.

Store uncooked pork belly wrapped tightly in the fridge for 3-4 days, or freeze for 6 months. Once smoked, the bacon keeps in the fridge for 1 week or frozen for 3 months. Slice just before serving for the best texture (it crisps up better this way).

Step-by-Step Instructions for BBQ Bacon Smoker

Master the technique for double-smoked bacon with crispy edges and deep, rich flavor.

Step 1: Prepare the Pork Belly and Create the Cure

Begin by patting the 2 lb Thick-Cut Pork Belly dry with paper towels to ensure the cure adheres properly. In a bowl, combine the 0.25 cup Kosher Salt, 0.25 cup Brown Sugar, 2 tbsp Coarse Black Pepper, 1 tbsp Paprika, 1 tbsp Garlic Powder, and 1 tbsp Onion Powder. Mix thoroughly to distribute the spices evenly.

This dry cure not only seasons the pork belly but also draws out moisture, which is essential for achieving the right texture. The combination of sweet, smoky, and savory elements ensures a balanced flavor profile in every bite.

Step 2: Apply the Cure and Add the Wet Rub

Rub the pork belly generously with 2 tbsp Yellow Mustard—this acts as a binder for the dry cure. Coat the pork belly evenly with the cure mixture, pressing it into the meat to ensure full coverage. Place the pork belly in a resealable bag or container and refrigerate for 24 hours to allow the cure to penetrate deeply.

After curing, rinse the pork belly under cold water to remove excess cure and pat dry again. Brush the surface with 2 tbsp Maple Syrup for a touch of sweetness and a glossy finish. This step enhances the bark formation during smoking.

Step 3: Set Up the Smoker and Begin the Smoke

Soak the 2 cups Hickory Wood Chips in water for 30 minutes to ensure a slow, steady smoke. Preheat your smoker to 200°F using the soaked wood chips for fuel. Place the pork belly directly on the smoker grates, fat-side up, to allow the fat to render and baste the meat naturally.

Smoke the pork belly at 200°F for 3-4 hours, or until the internal temperature reaches 150°F. Spritz the pork belly with 0.5 cup Apple Juice every 45-60 minutes to keep the surface moist and enhance the smoke absorption. The apple juice adds a subtle sweetness that complements the smoky flavor.

Step 4: Finish and Slice

Once the pork belly reaches 150°F, increase the smoker temperature to 225°F and continue cooking until the internal temperature reaches 165°F. This final push ensures the meat is fully cooked and tender while developing a deep, mahogany bark on the exterior.

Remove the pork belly from the smoker and let it rest for 15-20 minutes to allow the juices to redistribute. Slice the pork belly into ½-inch thick strips for a bacon-like texture. The result should be a perfect balance of smoky, sweet, and savory flavors with a crispy edge and tender center.

Storing and Reheating bbq bacon recipe smoker

Refrigerator Storage

Let your double-smoked bacon cool completely before storing. Wrap strips tightly in parchment paper, then place in a ziplock bag. It keeps in the fridge for up to 1 week—the smoky flavor actually deepens over time. ❄️

Freezer Storage

For longer storage, freeze slices flat on a tray first, then transfer to a freezer bag. This prevents sticking and lets you grab just what you need. It stays fresh for 3 months without losing texture or flavor.

Oven Reheating

Preheat to 375°F and place bacon on a wire rack over a baking sheet. Heat for 8-10 minutes until crispy. The wire rack ensures even airflow for that perfect texture.

Skillet Revival

My favorite method for small batches. Heat a cast iron skillet over medium heat and cook slices for 2-3 minutes per side. The skillet renders the fat beautifully. 🔥

Microwave Quick Fix

Lay strips between paper towels on a microwave-safe plate. Cook on high for 30-45 seconds, checking often. This works in a pinch but lacks the crispiness of other methods.

Pro Tip

Always reheat from frozen—no thawing needed. This prevents the bacon from becoming soggy. I’ve found this preserves the smoky bark better than thawing first.

Frequently Asked Questions