Smoked Rib Roast That Beats the Deli Counter for Sandwiches at Home
This is the kind of roast you make once and eat all week. It’s smoky, deeply seasoned, and sliced paper-thin for stacked, deli-style sandwiches that are way better than anything you’d buy from a restaurant.
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This is an easy smoker recipe, but you’re not cooking this like a prime rib dinner; you’re building flavor for sandwiches. Think bold seasoning, even smoke, and texture that holds up when sliced thin.
This full-color ebook cookbook features more than 50 of Chef Jenn’s tried, tested, and favorite smoker recipes! Enjoy:
- Smoked Beef Kabobs
- Smoked Chicken Thighs
- Smoked Bacon-Wrapped Pork Stuffed Jalapeno Poppers
- Smoked Spaghetti Squash with Herbs and so much more!
I love making a couple of these roasts in the fall. I then slice them and vacuum seal them in portions to get me through the winter. I do love me a good roast beef sandwich, and whether it’s a French Dip or Philly Cheesesteak, you’ll level up your game when you start with smoked roast beef.
Ingredients
- Boneless rib roast – A 3–4 pound roast works best for even cooking and easy slicing. Look for good marbling so the meat stays tender when sliced thin. You can use top round or eye of round for a leaner option, but it won’t be as juicy.
- Montreal Steak Seasoning – Adds bold, peppery flavor. If you don’t have it, use a mix of coarse black pepper, garlic powder, and onion powder.
How to Make Smoked Roast Beef for Sandwiches
Scroll down for the full recipe card with exact measurements and printable instructions.
Remove the roast from the fridge for up to two hours before smoking, to temper it. Pat the rib roast dry thoroughly using paper towels. Removing surface moisture helps the seasoning stick better and promotes even smoke coverage.
Place the roast on a sheet pan or tray and coat it evenly on all sides with the Montreal steak seasoning, pressing it in firmly so it adheres well. Preheat your pellet smoker to 185°F using hardwood pellets like oak, hickory, or a balanced blend. Allow the smoker to fully preheat so the temperature stays steady once the meat goes in.
Place the seasoned roast directly on the smoker grates, fat side up if applicable. Insert a digital meat thermometer or probe thermometer into the thickest part of the roast to monitor internal temperature accurately.
Smoke the roast low and slow at 185°F until the internal temperature reaches 125°F. This typically takes about 2 ½ to 3 ½ hours, depending on the size and thickness of the roast. Remove the roast from the smoker and place it on a cutting board or tray. Let it rest at room temperature for 1 hour so the juices redistribute and the carryover heat settles.
Wrap the roast tightly in plastic wrap or butcher paper and refrigerate it overnight, or at least 8 hours. This step is key to firming up the meat so it slices cleanly. Once fully chilled, slice the roast as thin as possible using a meat slicer. If using a knife, use a very sharp slicing knife and cut against the grain for the best texture.
Chef Jenn’s Recipe Notes
- I love using Montreal Steak Seasoning for my smoked meats, but you can use any blend you like.
- Temper your roast on the counter first before smoking. That means, take it out of the fridge for about an hour, even two, to warm up before smoking. This allows for a more even cook. I’ve tested it both ways – straight from the fridge and tempering first. Tempering results in an even color from the outside to the inside, without overcooking the exterior of the meat.
- Don’t skip the overnight chill or your slices won’t hold together
- Use a meat slicer to slice the meat in thin, even slices.
Make It A Meal
Pile the sliced beef onto crusty rolls with horseradish mayo, caramelized onions, or a swipe of mustard. Add a side of creamy coleslaw, kettle chips, or a simple potato salad, and finish with something easy like brownies or cookies if your family enjoys dessert after dinner.
Storage
Store sliced beef in an airtight container in the fridge for up to 4 days. For longer storage, portion and freeze it tightly wrapped. Thaw in the fridge and gently reheat with a splash of broth if you want it warm without drying it out.
Chilling isn’t optional if you want deli-thin slices. Cold meat firms up, which lets a slicer cut clean, even pieces instead of shredding the roast. This is standard practice in delis and butcher shops; slice warm meat and you’ll get uneven, ragged cuts.
Hardwoods like oak and hickory are the most reliable choices because they give you a balanced, classic smoke flavor that doesn’t overpower the beef. Fruit woods like apple or cherry can work, but they’re milder and won’t give you that deeper deli-style profile most people expect.
For sandwich-style roast beef, no. Searing builds a crust, which is great for serving as a roast dinner but not ideal when you want smooth, even slices. Skipping the sear keeps the exterior uniform and easier to slice thin.
As thin as you can get it without it falling apart—think deli roast beef. Thin slices give you a better bite and make the meat feel more tender, especially if you cooked it to a higher internal temperature like 165°F.
Smoked Rib Roast for Sandwiches
Ingredients
- 3-4 pound boneless rib roast
- ¼ cup Montreal steak seasoning
Instructions
- Pat the rib roast dry with paper towels and coat it evenly on all sides with the Montreal steak seasoning, pressing it in so it sticks well.
- Preheat your pellet smoker to 185°F using a hardwood pellet like oak, hickory, or a blend for balanced smoke.
- Place the seasoned roast directly on the grates and smoke low and slow until the internal temperature reaches 125°F.
- Remove the roast from the smoker and let it rest on the counter for 1 hour to allow juices to settle.
- Wrap the roast tightly and refrigerate it overnight so it firms up for clean slicing.
- Slice the chilled roast as thin as possible using a meat slicer for deli-style sandwich meat.
Notes
Chef Jenn’s Recipe Notes
- Use fresh coarse-ground Montreal seasoning for better texture and flavor
- Temper your roast on the counter first before smoking. That means, take it out of the fridge for about an hour, even two, to warm up before smoking. This allows for a more even cook. I’ve tested it both ways – straight from the fridge and tempering first. Tempering results in an even color from the outside to the inside, without overcooking the exterior of the meat.
- Don’t skip the overnight chill, or your slices won’t hold together
- Use a meat slicer to slice the meat into thin, even slices.
Nutrition
A Note on Nutritional Information
Nutritional information for this recipe is provided as a courtesy and is calculated based on available online ingredient information. It is only an approximate value. The accuracy of the nutritional information for any recipe on this site cannot be guaranteed.
