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There is no way to accurately predict when it will be done. As was already said, each piece of meat is different. Patience is a virtue, especially when smoking meat.
Chips don;t last long so you are going to be constantly refilling. If you have the ability to use chunks you might want to consider it. Apple and cherry goes well with butts.
The butt will stay a good long time time in the cooler. As long as the internal temps stay above 140 you are fine. I've had butts in a cooler all day and they were still way above 140.
I've dealt with the same thing. Just scrape off what you can, then wash it down (dont soak) with soap and water. Let it dry thoroughly then run a full basket of charcoal and get it nice and hot. let it cool down, scrape off any residue then reseason and ur fine.
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