Smoked Bologna “Chub” with Mustard Glaze – Easy Backyard BBQ Recipe

You ever stand in the meat aisle, stare at that big ol’ bologna chub, and think… “What on earth do I do with this thing?”

Yeah. Same.

The first time I smoked a bologna chub, I honestly expected a joke meal. Something goofy. Something nostalgic. What I got instead was one of the juiciest, smokiest, most flavor-packed BBQ bites I’ve ever pulled off my smoker. And once I brushed on that sticky mustard glaze? Game over.

If you love backyard BBQ, easy smoker recipes, and food that makes your neighbors wander over “just to say hi,” you’re in the right place.

Let’s talk smoked bologna with mustard glaze, how to do it right, and why this humble deli meat might become your new favorite cookout flex.

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Why Smoke a Bologna Chub in the First Place?

Let’s be honest. Bologna doesn’t scream gourmet.

But once you smoke it low and slow, something magical happens. The outside develops a deep smoky crust, the inside stays ridiculously juicy, and that glaze caramelizes into this sweet-tangy shell that makes you forget it started life as sandwich meat.

Here’s why this works so well:

• High fat content = stays moist
• Dense texture = holds smoke beautifully
• Affordable cut = feeds a crowd without wrecking your wallet
• Beginner-friendly = almost impossible to mess up

Ever wondered why BBQ joints in the South quietly keep smoked bologna on the menu? Now you know.

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Choosing the Right Bologna Chub

Not all bologna is created equal.

When I first made this, I grabbed the cheapest thing I saw. It worked… but it didn’t wow me. Since then, I’ve gotten picky.

What to Look For

• Large 3–5 lb bologna chub
• Thick, natural casing (peel it off before smoking)
• Minimal fillers
• Solid beef or beef/pork blend

I personally like using a high-quality deli-style bologna chub from the butcher. If you don’t have a local butcher, check larger grocery stores.

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The Equipment I Use (And Actually Recommend)

You don’t need fancy gear. But a few tools make life easier.

Here’s what I personally use:

• Smoker – I use a pellet grill like the Traeger Pro 575
• Meat Thermometer – The ThermoPro TP20 Wireless Meat Thermometer saves me from constantly opening the lid
• Sharp Knife for Scoring – Victorinox Fibrox Pro Chef’s Knife
• Silicone Basting Brush – OXO Good Grips Silicone Brush

FYI, the thermometer makes a massive difference. Guessing internal temp leads to dry bologna, and nobody wants that.

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Ingredients for Smoked Bologna with Mustard Glaze

Simple. Bold. No nonsense.

For the Bologna

• 3–5 lb bologna chub
• 2 tbsp yellow mustard (binder)
• 2–3 tbsp BBQ rub (your favorite)

For the Mustard Glaze

• ½ cup yellow mustard
• ¼ cup brown sugar
• 2 tbsp honey
• 1 tbsp apple cider vinegar
• 1 tsp smoked paprika
• ½ tsp black pepper
• Pinch cayenne (optional)

That glaze? It hits sweet, tangy, and slightly spicy all at once.

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Step-by-Step: How I Smoke a Bologna Chub

Let me walk you through exactly how I do this in my backyard.

Step 1: Preheat the Smoker

Set your smoker to 225°F.

I like using hickory or cherry wood. Hickory gives bold smoke flavor. Cherry adds color and slight sweetness. IMO, cherry makes it prettier for photos 🙂

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Step 2: Remove the Casing and Score It

Peel off the outer casing completely.

Now grab your knife and score the bologna in a crosshatch pattern about ½ inch deep.

Why score it?

• Allows smoke penetration
• Helps the glaze stick
• Creates crispy edges
• Prevents it from ballooning weirdly

Plus, it looks impressive.

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Step 3: Apply Mustard Binder & Rub

Rub a thin layer of yellow mustard over the entire chub.

Don’t worry — you won’t taste it. It just helps the seasoning stick.

Now coat generously with your favorite BBQ rub. Don’t be shy. This is a big piece of meat.

Let it sit 15–20 minutes while the smoker stabilizes.

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Step 4: Smoke It Low and Slow

Place the bologna directly on the smoker grates.

Smoke at 225°F for about 2–3 hours, or until the internal temperature hits 145–155°F.

I use my ThermoPro thermometer and stop opening the lid. Every time you peek, you lose heat. Resist the urge.

By hour two, you’ll see the cuts opening up and the surface darkening. That’s when things get exciting.

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Step 5: Brush on the Mustard Glaze

Mix all glaze ingredients in a bowl.

When the bologna hits around 140°F internal temp, brush on a thick coat of glaze.

Let it cook another 20–30 minutes so the glaze caramelizes.

You’ll see it tighten up and get glossy. That’s your cue.

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Step 6: Rest and Slice

Remove the bologna and let it rest 10–15 minutes.

Slice thick for sandwiches or cube it for burnt-end-style bites.

The edges will be slightly crisp. The inside stays juicy. That first slice always surprises me.

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Tips & Tricks I Learned the Hard Way

Let me save you from my early mistakes.

Don’t Crank the Heat

High heat dries it out fast. Stay at 225°F.

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Use Enough Rub

Bologna can handle bold seasoning. Under-seasoned bologna tastes… well… like lunch meat.

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Let the Glaze Set

Don’t brush glaze and immediately pull it off. Let it caramelize or it stays runny.

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Try Cubing for “Bologna Burnt Ends”

Slice into cubes, toss in extra glaze, and return to smoker for 30 minutes.

They disappear fast. I mean fast.

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Best Ways to Serve Smoked Bologna

You’ve got options.

Classic BBQ Sandwich

• Thick slice of smoked bologna
• White bread or brioche bun
• Extra glaze or BBQ sauce
• Pickles
• Coleslaw

Simple. Perfect.

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Bologna Burnt Ends

Cube it and serve with toothpicks at parties.

People will ask what it is. Don’t tell them at first. Watch their reaction when they love it.

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Breakfast Upgrade

Pan-fry leftover slices with eggs and toast.

Trust me. It beats regular bacon some mornings.

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Flavor Variations You Should Try

Once you master the basic mustard glaze, get creative.

Spicy Honey Glaze

Add extra cayenne and hot sauce.

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Maple Dijon Twist

Swap yellow mustard for Dijon and add maple syrup.

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Bourbon BBQ Glaze

Replace vinegar with 1 tbsp bourbon. Let alcohol cook off.

Each version changes the personality completely.

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Storage & Reheating

Store leftovers in an airtight container up to 4 days.

To reheat:

• Wrap in foil
• Heat at 275°F for 10–15 minutes
• Or pan-fry slices

Microwave works, but you lose texture. I only do that when I feel lazy :/

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Why This Recipe Works (From Experience)

I’ve made brisket. I’ve made ribs. I’ve made pork shoulder.

But smoked bologna surprises people.

It works because:

• It’s cheap but impressive
• It’s easy for beginners
• It absorbs smoke beautifully
• The mustard glaze balances the richness

And honestly? It feels nostalgic and new at the same time.

Ever bring something unexpected to a BBQ and steal the spotlight? That’s this recipe.