Over-The-Top Chili on a Pellet Grill?! ❄️🔥 Rollbox Smoke Test

It’s *below zero* in Wisconsin ❄️ — so I made *OVER-THE-TOP CHILI* on a pellet grill.
Using charcoal + wood chunks, I turned my pellet grill into a SMOKE MACHINE 🔥

This is the smokiest chili I’ve ever made on a pellet grill 🔥

If you’ve ever wondered how to get REAL smoke flavor on a pellet grill — especially for chili — this video shows exactly how I do it using charcoal and wood chunks without switching to an offset or stick burner.

🌶️ OVER-THE-TOP CHILI (PELLET GRILL VERSION)

In this video I make over-the-top chili on my Blaz’n Grill Works Grand Slam pellet grill, but with a twist — I added the Rollbox smoke box by Smoke Chasers to dramatically increase smoke flavor.

This method lets the meatball drip directly into the chili while absorbing heavy smoke, giving you bold BBQ flavor without needing an offset or stick burner.

I’m cooking in freezing Wisconsin winter temps, running the pit around 250°F, and showing you exactly how to get real smoke flavor on a pellet grill — even at higher temps.

@BlaznGrillWorks
https://mgrills.com/

@smokechasersbbq
https://smokechasersbbq.com/

🥩 WHAT’S IN THIS CHILI

• 2 lbs ground beef (over-the-top meatball)
• Bell peppers + onions
• Tomato sauce, diced tomatoes & Rotel
• Kidney beans (Wisconsin style 😉)
• Beef stock
• Garlic & jalapeños
• Meat Church chili seasoning
• Smoked using charcoal + wood chunks in the Rollbox

Simple ingredients. BIG flavor.

🔥 WHY THE *ROLLBOX* CHANGES EVERYTHING

Pellet grills don’t normally produce heavy smoke above ~225°F.

The Rollbox smoke box solves that by adding:
• Charcoal flavor
• Real wood chunk smoke
• Consistent smoke at higher temps

This turns a pellet grill into a legit smoke machine — perfect for chili, roasts, ribs, and long cooks where smoke matters.

❄️ COLD WEATHER BBQ TIPS

Cooking this in below-zero winter temps, I cover:
• Pellet grill performance in the cold
• Smoke retention in winter
• Why chili is one of the BEST cold-weather BBQ cooks
• How to avoid weak smoke flavor in winter

⏱️ COOKING METHOD (HIGH LEVEL)

1️⃣ Build chili base in a Dutch oven
2️⃣ Form a large over-the-top meatball
3️⃣ Smoke at ~250°F until meat hits ~140–145°F
4️⃣ Crumble meat into chili
5️⃣ Return to smoker and simmer/reduce
6️⃣ Finish around 190–205°F
7️⃣ Add cheese, sour cream, and enjoy 🔥

🧠 FINAL RESULTS

✔ Deep smoky flavor
✔ Rich chili body
✔ No bitter smoke
✔ Perfect winter comfort food

Honestly — one of the smokiest pellet-grill chilis I’ve ever made.

Be kind. BBQ brings people together!

Links:
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****LOST CANUCK ON-LINE STORE****
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****THERMOWORKS Items****
ThermoWorks RFX Wireless Starter Kit (Like Mine): https://thermoworks.sjv.io/BnQYXB
ThermoWorks Themapen One (Like Mine): https://thermoworks.sjv.io/mOBkg7
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****Huber Products Lone Star Accessories****
Huber Wood/Charcoal Split Basket: https://huberproducts.com/lone-star-grillz-wood-split-basket
Huber Main Deflector Plate: https://huberproducts.com/lone-star-grillz-deflector-plate-for-wood-split-basket
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Chapters:
0:00 Over-The-Top Chili on a Pellet Grill (Intro)
1:14 Lost Canuck BBQ Theme
1:39 Chili Ingredients Breakdown
2:46 Building the Chili Base
8:06 Making the Over-The-Top Meatball
11:00 Pellet Grill Setup (Cold Weather Tips)
12:12 Adding the Rollbox Smoke Box
13:28 Chili Goes on the Pellet Grill
15:01 Smoke Check (Rollbox in Action)
16:25 Crumbling the Meatball
18:00 Final Simmer on the Grill
18:12 Chili Taste Test 🔥
21:48 Rollbox Smoke Results
23:14 Final Thoughts & Tips

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