The Ultimate Over The Top Smoked Chili Recipe: A Flavor Revelation for Your Smoker

Prepare yourself for an extraordinary culinary experience with our Smoked Chili, famously known as Over The Top (OTT) Chili. This isn’t just a meal; it’s a gastronomic journey that promises to deliver the best chili you will ever taste. Imagine perfectly seasoned ground beef, slowly smoked until tender, its savory juices dripping into a rich, complex chili base below. This unique method, combined with a secret ingredient, creates an unparalleled depth of flavor that is truly out of this world. Whether you’re a seasoned pitmaster with a Big Green Egg or prefer the convenience of an electric smoker, this recipe is designed to transform your chili game forever. It’s a must-try, a true bucket list recipe that will have everyone asking for your secret.

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Why This Smoked Chili Recipe Works So Well

What makes this particular Over The Top (OTT) chili stand head and shoulders above the rest? It’s a careful balance of elements, each contributing to a symphony of flavors and textures that simply can’t be achieved through conventional methods. The magic begins with the foundation: a robust and perfectly balanced tomato base. We’ve fine-tuned the ratios of onion, garlic, and seasoning to ensure a savory backdrop that complements, rather than overpowers, the star ingredients. Just enough onion for sweetness, precisely the right amount of garlic for pungency, and a measured blend of spices create a harmonious base that forms the backbone of this incredible chili. And yes, there are beans – just enough to add substance without dominating the dish, though they are always optional.

Next, let’s talk about the ground beef. It’s crucial to select meat that isn’t too lean, as some fat is essential for both flavor and moisture, but also not so greasy that it overwhelms the chili. Our preference for 85% lean/15% fat or 80/20 ground chuck ensures a rich, succulent texture. Crucially, this beef is generously seasoned *before* it even sees the smoke. Ground beef always benefits from thoughtful seasoning, and here, we go the extra mile to infuse it with flavor from the start.

The “Over The Top” technique is truly what elevates this recipe. Instead of browning the beef in the pot, we smoke a seasoned “loaf” of ground beef directly above the simmering chili base. As the meat slowly cooks and absorbs that irresistible smoky flavor, its rendered juices and flavorful drippings fall directly into the chili below, enriching it with every drop. This continuous infusion of smoked beef essence during the cooking process is what makes the chili incredibly savory and deeply satisfying. Finally, a touch of dark chocolate stirred in at the end adds a surprising layer of earthy richness and complexity, pushing the flavor profile into truly unforgettable territory. It’s this combination of perfectly balanced ingredients, the unique smoking method, and that secret finishing touch that makes this the best chili of your life.

Essential Ingredients for Your Smoked Chili

Crafting the perfect Over The Top Smoked Chili requires a thoughtful selection of fresh, high-quality ingredients. Each component plays a vital role in building the layered flavors that make this recipe so exceptional. From the robust tomato base to the rich, smoked ground beef, here’s a breakdown of what you’ll need to gather.

Ingredients for the Chili Base

• Extra Virgin Olive Oil: Used for sautéing the aromatic vegetables, forming the savory foundation of your chili. It adds a subtle fruity note and helps prevent sticking.
• Fresh Vegetables: You’ll need two large yellow onions, diced for sweetness and body, three large green bell peppers (seeded and diced) for a fresh, slightly bitter counterpoint, and 3-4 cloves of garlic, minced, to provide essential pungent flavor. These aromatics are key to a well-rounded chili.
• Flavorful Seasonings: One tablespoon of quality chili powder and two teaspoons of ground cumin are crucial for developing that classic, warm chili taste. We’ll add an additional teaspoon of chili powder to the beef for extra punch.
• Robust Tomatoes: One large 28oz can of crushed tomatoes provides a rich, thick base, while one large 28oz can of petite diced tomatoes adds texture and a brighter tomato flavor without large chunks. This combination ensures a hearty, flavorful sauce.
• Red Kidney Beans: A single 15.5oz can of red kidney beans (drained and rinsed) offers a pleasant texture and traditional chili element. We opt for a moderate amount so they enhance the chili without overpowering it. Feel free to adjust the quantity to your preference, or omit them entirely if you’re not a fan.

Ingredients for the Smoked Ground Beef “Loaf”

• Quality Ground Beef: The cornerstone of this OTT chili is 2½ pounds of ground beef. We recommend an 85% lean/15% fat blend, or 80% lean/20% ground chuck. This fat content is ideal for flavor and moisture retention during smoking, ensuring your chili remains rich and delicious, not overly dry or greasy. Avoid anything leaner than 85%.
• Worcestershire Sauce: Two teaspoons of Worcestershire sauce contribute a deep umami flavor, enhancing the savory notes of the beef and adding complexity.
• Beef Seasonings: Two teaspoons of kosher salt for essential seasoning, half a teaspoon of fresh cracked black pepper for a pungent kick, and one teaspoon of Montreal steak seasoning, which brings a robust blend of garlic, onion, and spices perfect for beef.

Last, but certainly not least, is our secret ingredient: a quarter cup of dark chocolate morsels. This isn’t about making your chili sweet; instead, the dark chocolate (choose one with at least 70% cacao) introduces an earthy richness and a profound depth of flavor that subtly rounds out the spice and acidity, pushing this recipe over the edge into truly gourmet territory.

How to Make Unforgettable Over The Top Smoked Chili

Making this incredible smoked chili is a process broken down into simple, manageable steps, starting with the base and moving to the unique smoking method. Follow these instructions carefully to achieve maximum flavor.

Prepare the Chili Base

The chili base comes together quickly on your stovetop. In a 6-quart Dutch oven (or another non-reactive pot, especially if your cast iron is not well-seasoned), heat the extra virgin olive oil over medium-high heat. Add the diced yellow onions, green bell peppers, and minced garlic. Sauté these aromatics for about 5 minutes, or until the onions become translucent and softened. This initial step builds a crucial flavor foundation. Once softened, remove the pot from the heat and stir in the chili powder, cumin, crushed tomatoes, petite diced tomatoes, and the drained and rinsed red kidney beans. Give it a good stir to combine all the ingredients. Your flavorful chili base is now ready for the smoker!

Smoking in the Big Green Egg

For Big Green Egg enthusiasts, setting up for indirect smoking is key to preventing the bottom of your Dutch oven from burning.

1. Setup: Insert your plate setter (also known as a convEGGtor) with the legs pointing upwards. This creates a barrier for indirect heat. Bring the internal temperature of your Big Green Egg to a steady 275°F-300°F.
2. Add Wood: Once at temperature, add your wood of choice. We highly recommend hickory chunks for this recipe as it imparts a beautiful, deep smoky flavor that complements the beef and chili perfectly. Remember, a little hickory goes a long way, especially with ground beef, so you won’t need an excessive amount.
3. Assemble Smoker: When you have a good, steady smoke, place a grill grate directly on the plate setter. Carefully place your Dutch oven, uncovered, onto this grill grate.
4. Position the Beef: Now for the “over-the-top” part! Place another grill grate directly on top of the Dutch oven. Alternatively, use your EGGspander or extender kit to create a second tier above the Dutch oven. Form your seasoned ground beef mixture into a “loaf” and place it on this upper grill grate.
5. First Smoke Phase: Close the lid and smoke for 2 hours, or until the internal temperature of the beef loaf reaches 150°F. Use a reliable meat thermometer to ensure accuracy. During this time, the beef will infuse the chili below with incredible smoky flavor and rich juices.
6. Combine & Simmer: Once the beef reaches 150°F, remove it from the grill grate. Break it up into small crumbles and stir it directly into the chili in the Dutch oven.
7. Second Smoke Phase (Flavor Blending): Place the Dutch oven back on the grill grate. Continue cooking on the Egg for another 2 hours. This period allows the flavors to meld beautifully and the meat to tenderize further. Crucially, do not add more wood during this phase. The beef has already absorbed plenty of smoke, and additional wood could lead to an overpowering, acrid taste.
8. Finishing Touch: After the second cooking phase, remove the Dutch oven from the Egg. Stir in the dark chocolate morsels until they are fully melted and incorporated. Serve your ultimate smoked chili hot, with your favorite toppings!

Smoking in an Electric Smoker

Achieving delicious Over The Top Smoked Chili in an electric smoker is equally straightforward.

1. Setup: Preheat your electric smoker to a steady temperature of 275°F-300°F.
2. Add Wood: Add your chosen wood, such as hickory chunks, to the smoker’s wood chip tray once it reaches the target temperature. Allow it to start producing a good, steady smoke.
3. Assemble Smoker: Place your Dutch oven, filled with the chili base and uncovered, on one of the smoker’s grates.
4. Position the Beef: Place your seasoned ground beef “loaf” on a second grate positioned directly above the Dutch oven. This allows the beef drippings to fall into the chili below.
5. First Smoke Phase: Close the smoker door and cook for 2 hours, or until the internal temperature of the beef reaches 150°F. Monitor the temperature with a reliable meat thermometer.
6. Combine & Simmer: Carefully remove the beef loaf from the smoker. Break it into small crumbles and stir it thoroughly into the chili in the Dutch oven.
7. Second Smoke Phase (Flavor Blending): Return the Dutch oven to the smoker. Continue cooking for an additional 2 hours to allow the flavors to deepen and the chili to thicken. Do not add more wood during this phase, as the chili and beef will have already absorbed sufficient smoke.
8. Finishing Touch: Remove the Dutch oven from the electric smoker. Stir in the dark chocolate morsels until completely melted and blended. Your amazing smoked chili is now ready to be served and enjoyed!

Discover More Smoker Recipes

If you’ve loved the unique flavors of Over The Top Smoked Chili, expand your horizons with these other fantastic smoker recipes from our kitchen. Each offers a distinct and delicious way to utilize your smoker!

Expert Tips for Your Best Smoked Chili

To ensure your Over The Top Smoked Chili is nothing short of perfection, here are some invaluable tips gathered from extensive testing and experience:

• Choosing Your Wood: While we highly recommend hickory for its balanced and robust smoky flavor, feel free to experiment with other wood types. Apple or cherry wood can offer a milder, sweeter smoke, while oak provides a medium, classic BBQ flavor. However, we advise against using mesquite, as its strong and often intense flavor can easily overpower the nuanced ingredients of this chili, resulting in a less balanced dish.
• Less is More with Smoke: It might seem counterintuitive for a smoked recipe, but you genuinely don’t need a lot of wood or constant smoke for this chili. Ground beef, with its relatively porous texture and many nooks and crannies, acts like a sponge, soaking up smoke flavor very efficiently. Once your initial wood chunks have burned out and stopped producing thick smoke (usually after the first hour or two), resist the temptation to add more. We’ve learned from experience that adding additional wood can lead to an overly smoky, sometimes bitter, final product. The goal is a rich, smoky undertone, not an overwhelming smoke flavor.
• Knowing When Your Chili is Done: Since this chili cooks at a lower temperature, you won’t see a rolling boil or vigorous simmer. Instead, look for a gentle “bubbly bubble” occasionally. The chili is ready when the crumbled meat is thoroughly tender, all the ingredients have had ample time to meld together into a cohesive and complex flavor profile, and the sauce has thickened to your desired consistency. Taste often in the final hour to judge the blend of flavors.
• Make Ahead and Freezing: This smoked chili is an excellent candidate for meal prep. It freezes beautifully! Allow the chili to cool completely before transferring it to airtight plastic containers or freezer bags. For extra protection against freezer burn, press a piece of plastic wrap directly onto the surface of the chili before sealing. It can be stored in the freezer for up to 3 months.
• Reheating Leftovers: Smoked chili reheats wonderfully, often tasting even better the next day as the flavors continue to deepen. Reheat gently on the stovetop over low to medium-low heat, stirring occasionally, or in the microwave. Add a splash of broth or water if it’s too thick.
• The Bean Debate: As with any chili, the inclusion of beans is a matter of personal preference. We’ve found that one can of red kidney beans provides just the right amount of texture and classic chili feel without overwhelming the dish. If you prefer a bean-free chili, simply omit them. If you love beans, feel free to add another can!
• Dutch Oven Selection: Tomatoes are acidic, and this can react with unseasoned cast iron, potentially imparting a metallic taste or even damaging the seasoning of your pan. For best results and to ensure the purest flavor, we recommend using an enameled Dutch oven or another non-reactive pot (like stainless steel) for your chili base. If your cast iron Dutch oven is very well-seasoned and you’re confident in its non-reactive properties, it can also work.

Frequently Asked Questions (FAQs) About Smoked Chili

If you love smoking “Over-the-Top,” check out my Smoked Meatballs Marinara recipe too. It’s another fantastic way to utilize this unique cooking method!