Smoking a ham on a pellet grill is one of the most rewarding culinary projects you can undertake. While most hams purchased at the grocery store are already “city hams” (meaning they are precooked and smoked), the process of double-smoking them on a pellet grill elevates the flavor to a gourmet level. This method infuses a deep, wood-fired essence into the meat while allowing you to apply a custom glaze that caramelizes into a sticky, sweet, and savory crust.
Whether you are preparing a centerpiece for a holiday feast or simply want the best sandwich meat of your life, mastering the pellet grill technique is the key. Pellet grills are particularly well-suited for ham because they maintain incredibly consistent temperatures, acting like a convection oven fueled by real hardwood.
Choosing the Right Ham for Your Pellet Grill
Before you even fire up the grill, the success of your meal depends on the quality and type of ham you select. There are three primary categories you will encounter at the butcher shop or grocery store.
City Hams versus Country Hams
City hams are the most common. They are cured in a liquid brine and are typically sold fully cooked. These are the “heat and eat” hams that benefit most from a second round of smoking on a pellet grill. Country hams, conversely, are dry-cured in salt and aged for months. They are much saltier and more intense, often requiring soaking before cooking. For the classic juicy, glazed smoked ham experience, stick with a city ham.
Bone-In versus Boneless
For the best flavor and moisture retention, bone-in is the way to go. The bone acts as a heat conductor, helping the ham cook more evenly from the inside out, and it provides a richer flavor to the surrounding meat. Plus, you get a ham bone to save for soups or beans later. Boneless hams are easier to slice but tend to dry out more quickly on the grill.
Spiral-Cut versus Whole
Spiral-cut hams are incredibly convenient because they come pre-sliced. However, they are prone to drying out during a long smoke because the heat can penetrate between the slices. If you choose a spiral-cut ham, you must be diligent about basting and perhaps shortening the cook time. A whole (non-sliced) ham is more forgiving and stays juicier, though it requires a bit more effort when it’s time to serve.
Preparing Your Ham for the Smoke
Preparation for a double-smoked ham is relatively simple because the meat is already cured. You aren’t starting from raw pork; you are enhancing what is already there.
Trimming and Scoring
If your ham has a thick layer of fat on the exterior, you may want to trim it down to about a quarter-inch. Once trimmed, use a sharp knife to score the fat in a diamond pattern. Cut about a half-inch deep. This serves two purposes: it allows the rendered fat to escape, and it creates “channels” for your rub and glaze to penetrate the meat.
Applying a Binder and Rub
While ham is naturally flavorful, a dry rub adds a necessary bark. Use a light binder like yellow mustard or maple syrup to help the spices stick. For the rub, a blend of brown sugar, paprika, garlic powder, onion powder, and a touch of black pepper works beautifully. Since ham is already very salty from the curing process, be cautious about adding extra salt to your rub.
Setting Up Your Pellet Grill
The beauty of a pellet grill is the “set it and forget it” convenience, but you still need to make a few strategic choices regarding wood and temperature.
Selecting the Best Pellets
For ham, you want a wood that complements the natural sweetness of the pork without overpowering it. Fruitwoods are the gold standard here.
- Apple: Provides a mild, sweet smoke.
- Cherry: Imparts a beautiful reddish hue to the meat and a subtle tartness.
- Pecan: Offers a rich, nutty flavor that pairs perfectly with brown sugar glazes.
- Hickory: A stronger option if you want a more “traditional” BBQ profile.
Preheating the Grill
You want to cook “low and slow” to ensure the ham heats through without the exterior becoming tough or leathery. Preheat your pellet grill to 225°F or 250°F. Starting at a lower temperature like 225°F allows for more smoke penetration during the first few hours of the cook.
The Smoking Process
Once the grill is up to temp, place the ham directly on the grill grates. If you are using a half-ham, place it cut-side down. This protects the meat from direct heat and helps retain moisture.
Monitoring the Internal Temperature
Since the ham is already cooked, your goal is to reach an internal temperature of 140°F. This is the sweet spot where the ham is hot throughout but hasn’t started to dry out. Use a reliable meat thermometer to track progress. On average, expect the process to take about 15 to 20 minutes per pound at 250°F.
Basting for Moisture
Every hour, spritz the ham with a liquid to keep the surface moist. A mixture of apple juice, apple cider vinegar, or even a splash of bourbon works wonders. This moisture also helps the smoke “stick” to the meat, enhancing that smoky ring and flavor profile.
Crafting the Perfect Glaze
The glaze is the “grand finale” of your smoked ham. It should be applied only during the last 30 to 45 minutes of the cook. If you apply it too early, the high sugar content will burn, leaving you with a bitter, blackened crust instead of a translucent, mahogany finish.
A Classic Honey Bourbon Glaze
A fan-favorite glaze involves simmering the following ingredients in a saucepan until thickened:
- 1 cup brown sugar
- 1/2 cup honey or maple syrup
- 1/4 cup bourbon
- 2 tablespoons Dijon mustard
- 1/2 teaspoon cinnamon
Application Technique
When the ham reaches an internal temperature of about 130°F, generously brush the glaze over the entire surface, ensuring it gets into those diamond-scored grooves. You can repeat this process every 15 minutes until you hit the final target temperature of 140°F. If you want a truly “shellacked” look, you can briefly turn the grill up to 350°F for the last 5 minutes to caramelize the sugars, but watch it closely to prevent burning.
Resting and Slicing
Once the ham reaches 140°F, remove it from the pellet grill. This is the most difficult part: you must let it rest. Transfer the ham to a cutting board and tent it loosely with aluminum foil.
The Importance of the Rest
Resting for 15 to 20 minutes allows the juices to redistribute through the muscle fibers. If you slice it immediately, all that precious moisture will run out onto the board, leaving you with dry meat. During the rest, the carryover heat may bring the internal temperature up to 145°F, which is perfectly fine.
Slicing for Service
For a bone-in ham, cut slices parallel to the bone until you hit it, then make a cut along the bone to release the slices. If you used a spiral-cut ham, simply follow the pre-cut lines. Serve warm with any remaining glaze on the side.
Common Mistakes to Avoid
Even with the best equipment, a few common errors can ruin a good ham.
- Overcooking: This is the number one mistake. Remember, you are reheating, not cooking from scratch. Anything over 150°F internal temperature will start to turn the texture “hammy” in a bad way—dry and stringy.
- Too Much Salt: Most commercial hams are salt-heavy. Avoid rubs with high salt content and stick to sweet or acidic profiles.
- Ignoring the Ambient Temp: If it’s a very cold or windy day, your pellet grill might struggle to maintain heat, or it might consume pellets faster. Keep an eye on your pellet hopper.
Storing and Using Leftovers
Smoked ham leftovers are arguably as good as the main meal. Store leftover ham in an airtight container in the refrigerator for up to five days, or freeze it for up to three months.
The smoky flavor makes these leftovers perfect for:
- Ham and split pea soup.
- Breakfast hash with potatoes and onions.
- Cuban sandwiches with Swiss cheese and pickles.
- Diced into a cheesy quiche or frittata.
FAQs
What is the best temperature to smoke a ham on a pellet grill?
For the best results, you should set your pellet grill to 225°F or 250°F. This allows the ham to heat through slowly while absorbing the maximum amount of smoke flavor without drying out the exterior.
How long does it take to smoke a ham per pound?
You should generally plan for about 15 to 20 minutes per pound when smoking at 250°F. However, because every ham and grill is different, you should always cook to an internal temperature of 140°F rather than relying strictly on the clock.
Do I need to wrap the ham in foil while smoking?
You do not need to wrap the ham for the entire duration, as this would prevent the smoke from reaching the meat. However, if you notice the exterior is getting too dark before the center is warm, you can loosely tent it with foil to protect it.
Can I smoke a ham that isn’t pre-cooked?
Yes, but that is a different process called “fresh ham.” A fresh ham is raw pork leg and requires a much longer cooking time to reach a safe internal temperature of 145°F and a higher finishing temp if you want a pulled texture. The guide above is specifically for the much more common cured city ham.
Should I put water in the pellet grill?
While not strictly necessary on most modern pellet grills, placing a small water pan on the grate near the ham can help maintain a humid environment. This helps prevent the surface of the ham from drying out during the multi-hour smoking process.