Smoked Over the Top Beef & Sausage Chili with Fire In The Hole Seasoning

Over-the-top chili is one of the easiest ways to pack serious smoke flavor into a pot of chili. By smoking the meat above the pot, every drip of rendered fat and seasoning feeds the chili below.

This version leans into Burn Pit BBQ flavor—ground beef, sausage, and Fire In The Hole doing the heavy lifting—while still building a balanced chili base from scratch. No packets. No filler. Just a solid, repeatable cook.

Listen to the Podcast where we break it down!

Smoked Over the Top Beef & Sausage Chili

Yield

8–10 servings

Smoker Temp

225–250°F

Total Cook Time

5–6 hours

Needed Equipment

• Smoker (pellet, offset, kettle, or vertical smoker)
• Large Dutch oven or heavy-duty cast iron pot
• oscarware Disposable Grill Topper (to suspend meat over the chili)
• Grill-safe thermometer or instant-read thermometer
• Heat-resistant gloves
• Long-handled spoon or ladle
• Cutting board and sharp knife

Optional but Helpful

• Chimney starter (if running charcoal)
• Wood chunks or chips (oak, pecan, or hickory)
• Aluminum foil (for easy cleanup under the rack)

Ingredients

Meat

• 2 lb 80/20 ground beef
• 1 lb pork breakfast sausage (or hot sausage for more kick)
• 2 ½ Tbsp Burn Pit BBQ Fire In The Hole seasoning
• 1 tsp kosher salt
• 1 tsp coarse black pepper

Chili Base

• 2 Tbsp neutral oil (avocado or canola)
• 2 large yellow onions, diced
• 5 cloves garlic, minced
• 4 cans (14.5 oz each) fire-roasted diced tomatoes (with juice)
• 1 can (15 oz) tomato sauce
• 1 can (7 oz) chipotle peppers in adobo, chopped (use half for less heat)
• 1 bottle (12 oz) amber or lager beer
• 1 cup beef broth
• 1 whole jalapeño (optional)
• 2 cinnamon sticks (optional, remove later)
• 2 oz dark chocolate (70–85% cacao)

Supporting Chili Spices

(Fire In The Hole is the primary seasoning — these support it, not compete with it)

• 2 Tbsp chili powder
• 1 Tbsp paprika (smoked preferred)
• 2 tsp ground cumin
• 1 tsp onion powder
• 1 tsp garlic powder
• 1 tsp dried oregano
• ½ tsp cayenne pepper (optional)

Instructions

1. Prep the Smoker

Set smoker to 225°F using oak, pecan, or hickory.

2. Build the Chili Base

1. Heat oil in a large Dutch oven.
2. Add onions and cook until softened, about 5 minutes.
3. Stir in garlic and cook 30 seconds.
4. Add tomatoes, tomato sauce, chipotles, beer, beef broth, jalapeño, cinnamon sticks, dark chocolate, and all supporting chili spices.

Stir well and bring to a light simmer.

Place the uncovered Dutch oven on the smoker.

3. Season & Smoke the Meat

1. Combine ground beef and sausage.
2. Season evenly with Fire In The Hole, salt, and pepper.
3. Form into a tight ball or oval.
4. Place on an oscarware Disposable Grill Topper directly above the chili pot so drippings fall into the chili.

Smoke until internal temp reaches 165°F, about 2–3 hours.

Grilling & Smoking Tips

• 80/20 beef and sausage provide better drippings and richer chili.
• Keep the pot uncovered to maximize smoke absorption.
• Chili thickens naturally as it cooks—avoid adding flour or cornstarch.

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Extra Flavor & Pairing Ideas

• Finish with a splash of Worcestershire or apple cider vinegar.
• Serve with grilled cornbread or jalapeño cheddar biscuits.
• Tastes even better the next day.

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FAQ

Can I cook this without a smoker?
Yes. Brown the meat separately, then simmer everything indoors for 3–4 hours.