HELP!!! What happened with my brisket and will it happen again?!?

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bfg scott

Newbie
Original poster
Sep 6, 2017
10
12
Ontario, Canada
I've been lurking here for quite awhile and just recently signed up. In that time, I've seen many of these "help" threads where the people replying say they need more info. Well, prepare for "more info".

For those who don't want to read through everything, my 14.5 lb brisket was done in 10 hours. Being a brisket rookie, this seemed REAL quick. I have a big cook coming up next week where it has to be done on time(ish) and need to know if this is normal or did I miss something. For the details, read on. To see the final Jeopardy question, scroll down to the red text.

So I'm going to be doing a BBQ for work next week with about 80 people. I plan on doing a brisket, 2 or 3 pork shoulders and some boneless chicken thighs. I have a Weber 22.5" Smokey Mountain and just bought a Dyna-Glo wide-body vertical offset. This guy right here...


I read a couple dozen pages here before buying and building it and did the recommended mods as far as sealing it and adding a heat baffle at the firebox (hard to see in the crappy cell phone pic).

Last weekend, to practice for next week, I bought a 14.5 lb brisket and since I was going to be running the smoker anyway, I told a couple fellow "meat enthusiasts" at work that if they wanted to buy the meat, I'd do a pork butt for them. I wound up with 6, 8 and 10 pound butts.

Brisket (Lego Mr. T for scale)


The night before, I salted it and injected with beef broth. The next night, I rubbed it about an hour before going on. This is my first full brisket (did an 8 lb once) and I figured at 1.5 hours a pound, I'd get it on at 6:30 pm Saturday so it would be done a bit after noon on Sunday and I could rest it in the cooler for a couple hours.

Here comes the info;

I ran briquettes in the Dyna-Glo along with some hickory chunks for the first hour or so. I had a water pan at the bottom left (see first photo). My temps were pretty consistent in the 220 to 235 range (the odd spike after adding a fresh batch of lit coals). I was using a Weber iGrill with one probe in the beef, one for the smoker temp and one for the outside temp. I kept a detailed log of smoker temp/meat temp/outside temp for every half-hour of the cook but I won't go that crazy and post it all here.

The brisket going in


At 6:30, the meat went on (fat side down) at 52 degrees, at 8pm it was 89 and when I added coals at 9:45, it was at 121. From that point on, it went up about 10 degrees an hour so I figured when I was ready to put the pork on at 1:00 am, it would be close enough to the stall that I would wrap the brisket. At 1 am, it was at 155 degrees so I wrapped it in foil (just a light spritz of 50/50 water and apple juice) and threw it in with the butts.

Here it is before wrapping


After babysitting the butts for an hour and adding applewood chunks every 20 minutes for an hour and a half, I figured I could squeeze in a couple hour nap before I needed to add coals. At 2:25 am, the brisket was at 161 when I went to sleep. I had added a few lit coals and some wood so the smoker temp was 235.

At 4:40 am, I woke up, looked at the temps and panicked! The smoker was at 226 and the brisket was at 199 degrees!!! In the 2 hours I was asleep, it had gone up 40 degrees. At 5 am, I took it off at 203 degrees. I probed it with my instant read in about 20 different places and got 202 to 204. It was done in 10.5 hours. WTF?!?!

I threw an extra layer of foil on it (to cover all the probe holes) and put it in a cooler with a bunch of towels. Luckily, it took until about dinner time to get to 145 before I sliced it. It meant I didn't really get a good bark, but what are you gonna do.

Before slicing


Here's my problem

For the warm-up cook, being 10-plus hours early wasn't the end of the world. That's why I did a practice run, right? But for next week, I need to serve 80 people at noon. In fact, for brisket, I want it ready around 7 to 8 AM so I can rest it in the cooler before slicing. If I go by this first experience and start cooking my brisket at 8pm, will it take 10 or 11 hours again? If it takes 20, I'm screwed. I'll probably go with a 16 pounder so what time do I need to put it on?
 
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You can't plan big pieces of meat that close. Never works out the way you want it.

You didn't get good bark because you wrapped it. The Texas crutch (wrapping) does two things. It speeds up the cooking process, and it destroys bark. I only use it when I'm running way behind which is almost never.

And to be honest I inject no more than an hour before smoking and then I rub. No salt the day before, no injection the day before.

Also 1 brisket for 80 people is way off. Even adding Pork and chicken your going to want to do 3 briskets minimum. It goes fast.

Good luck.
 
Im going to ask the obvious but did you confirm the accuracy of your temp probes?
 
I'd do 2 briskets, put them on at the same time you did before and just not use the crutch. Then if the stall is too long wrap it, and raise temp to finish quicker.
 
Wow! That was fast!

As far as the probes...
No, I never tested them. They're all Weber iGrill probes. A couple days earlier, when I did the burn in on the new smoker, I ran all 4 probes in the top and bottom corners of the cook chamber to see what the variations were. I even moved them around a couple times. If they're off, then they're ALL of by the same amount. I also probed the brisket with a hand held that I have tested as bang-on it it was the one that gave me the 202 to 204.

As far as meat quantity, I'm cooking, the boss is buying. This is my first big cook so I'm open to suggestions. 80 people is the max. It may be more like 70. We're planning on a 16 lb brisket, three 10 lb pork butts and about 40 bucks worth of boneless chicken thighs. I'm also doing homemade mac n cheese and there will be coleslaw, potato salad, etc.
 
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You'll lose 40-50% of that pork as it renders down. So plan on 15 pounds of pulled to be safe. At 1/4# per person that'll feed roughly 60 people if my slightly intoxicated math is correct.

$40 in chicken thighs is a lot of chicken!

Big problem is people love brisket. Your gonna want to push for 2 16+ pounders. Your burnt ends will disappear faster than anything and your brisket slices will be next.
 
The boss likes brisket, so as long as he gets some, it's every man for himself after that. Then the rest of the peasants will have to make do with pulled pork and chicken. :biggrin:
And we're talking 40 Canadian dollars, so maybe not that much chicken.

BTW, here's the butts when the mac 'n' cheese went in

And when they came off
 
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Very nice smoke!  
points1.png
What was the grade of the brisket?  A prime might cook faster then a select.  I've also smoked briskets that were very fatty and they cooked much faster.

Mike
 
Thanks. The beef was Canadian AAA which I think is the equivalent to USDA Choice.

And my mistake...
The photo of the three butts on the one shelf was a couple hours before completion. Here the 10 lb before and after pulling. Again, sorry for the crappy cell phone pics.

 
Here's my problem

For the warm-up cook, being 10-plus hours early wasn't the end of the world. That's why I did a practice run, right? But for next week, I need to serve 80 people at noon. In fact, for brisket, I want it ready around 7 to 8 AM so I can rest it in the cooler before slicing. If I go by this first experience and start cooking my brisket at 8pm, will it take 10 or 11 hours again? If it takes 20, I'm screwed. I'll probably go with a 16 pounder so what time do I need to put it on?
Hi there and welcome!

One thing I can see that probably sped up your cook was that you had the smoker temp probe above the brisket.

I guarantee that the rack above the brisket is at a lower temp.  I would put money to say there is at least a 10 degree difference between the brisket rack and the rack you had the smoker probe on.

So if you were smoking at 220-235F measuring that temp from the smoker probe on the rack above the brisket, I would strongly think that the brisket level temp was probably closer to 250F or more.

Also the 2nd thing I think sped up your cook was how early you wrapped the brisket.  Ive noticed that when I wrap beef  in foil it goes from about 165F to 203F in about 2 hours or so.  

That is consistent with what you encountered.  So keep that in mind for your next smoke and see if that becomes a pattern ( I bet it does).

Best of luck with your next smoke.  I hope this info helps :)
 
Yeah, I didn't wait for it to actually stall before wrapping it. The timing wound up that I had to add coals and put on the pork anyway right around the time the brisket was hitting the mid to high 150s.

As far as grill temps, I'll run some more tests as I get used to the new smoker but when I did the burn in, the difference from top to bottom (6 shelves apart) was no more than 5 to 10 degrees. The only spot that was out by more was the bottom left, opposite the firebox. I might need to extend the baffle a bit.
 
Yeah, I didn't wait for it to actually stall before wrapping it. The timing wound up that I had to add coals and put on the pork anyway right around the time the brisket was hitting the mid to high 150s.

As far as grill temps, I'll run some more tests as I get used to the new smoker but when I did the burn in, the difference from top to bottom (6 shelves apart) was no more than 5 to 10 degrees. The only spot that was out by more was the bottom left, opposite the firebox. I might need to extend the baffle a bit.
I believe the wrapping mitigated the stall or shortened it for sure.

Testing while the smoker is loaded up is definitely the way to go.   I would bet money that you won't see the same 5-10 degree difference between the racks once the brisket is loaded in there.  I believe it would trap and absorb a lot of heat as the air/heat travels upwards.  I run 3 smoke probes and 3 meat probes in my heavily moded MES40 and even across a single rack I get 5-10 degree differences from left/right/center on a single rack and lower temps on the next racks as things go up.

It's all a game of figuring out the behavior and trying to win the consistency battle.  Not only do you fight temp differences on a rack level and between racks, you also fight temp difference with every type of smoke you do.  

For instance I brine my whole chicken, chicken breasts, and turkey drums/thighs and for the life of me I can barely (if at all) hit a set temp of 275F+ if I load everything and turn on the smoker.  I believe the moisture and humidity created by the brined meat simply won't let my smoker get hot enough fast enough.  With this type of smoke I have to get the smoker above my set temp and then load everything quickly so it drops to just under my set temp.

With a brisket or pork butt I have no such problem I just loaded it up and turn it on and boom it hits 275F with no trouble.  

Temps and behavior can just be weird all the time but the battle for consistent and reliable behavior is part of the craft and knowing how different types of loads/smokes/cooks/configurations work is all part of the game :) 
 
I'm almost leaning towards putting the brisket and butts on the Weber Smokey Mountain for the long smoke. Then the morning of, use the Dyna-Glo for the mac and cheese, baked beans, and chicken.

Would a WSM handle a 16 lb brisket and three 10 lb butts at once? I know the specs say yes, but in the real world...
 
I'm almost leaning towards putting the brisket and butts on the Weber Smokey Mountain for the long smoke. Then the morning of, use the Dyna-Glo for the mac and cheese, baked beans, and chicken.

Would a WSM handle a 16 lb brisket and three 10 lb butts at once? I know the specs say yes, but in the real world...

Yes. You may have to tie up the butts to make them a little more compact. It will be tight, but three butts should fit. They shrink as they cook.
 
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