Texas Smoked Beef Sausage

Ingredients

• 2 lbs ground beef chuck (80/20 blend)
• 1.5 tsp kosher salt
• 1 tsp freshly cracked black pepper
• 1.5 tsp garlic powder
• 1 tsp onion powder
• 1 tsp smoked paprika
• ½ tsp cayenne pepper
• ¼ tsp pink curing salt (sodium nitrite)
• ¼ cup ice water
• 4 oz hog casings, soaked in warm water for 30 minutes

Instructions

1. 1

   Measure out 2 lbs of ground beef chuck (80/20 blend) and place it in a large stainless steel bowl. Chill the bowl and all equipment in the freezer for 15 minutes — cold meat holds together better and prevents the fat from smearing into the surrounding meat, giving you those distinctive coarse texture pockets that characterize authentic Texas sausage.

2. 2

   Measure out 1.5 tsp kosher salt, 1 tsp freshly cracked black pepper, 1.5 tsp garlic powder, 1 tsp onion powder, 1 tsp smoked paprika, 0.5 tsp cayenne pepper, and 0.25 tsp pink curing salt into a small bowl. Stir to combine evenly so the spices distribute uniformly through the meat.

3. 3

   Remove the hog casings from their package and lay them in a bowl of warm water for 30 minutes to soften. Once pliable, gently run cool water through the inside of each casing with your fingertip — this removes excess salt and prevents tears during stuffing.

4. 4

   Remove the chilled bowl of ground beef and add the spice mixture. Pour in 0.25 cup ice water — the cold water binds the meat without heating it and creates a tacky texture that holds casings tight. Using your hands, mix gently but thoroughly, pinching and folding the meat for about 2 minutes until the mixture becomes slightly tacky and just holds together. Do not overmix or the sausage will become dense and pale.

5. 5

   Set up a sausage stuffer (hand-crank or electric), and slide one soaked hog casing onto the nozzle, leaving about 2 inches of casing dangling at the start. Feed the meat mixture slowly into the hopper, turning the crank steadily so the casing fills evenly without air pockets. As you stuff, gently guide the casing off the nozzle with your other hand — the pressure should come from the stuffer, not your pull. Stop about 1 inch from the end and slide the casing off.

6. 6

   Once all four casings are stuffed, use a sausage pricker or clean needle to gently poke 10–12 tiny holes over the length of each sausage. These pinpricks let steam escape during smoking and prevent the casings from bursting. Lay the sausages on a parchment-lined sheet tray and refrigerate for at least 2 hours, ideally overnight — this sets the shape and allows flavors to meld.

7. 7

   Prepare your smoker for low-and-slow cooking: arrange hardwood coals (oak, hickory, or mesquite are traditional for Texas sausage) on one side, leaving the other side empty. Aim for a chamber temperature of 275°F–300°F. If using a kettle grill, arrange coals in a half-moon, place a drip pan filled with water on the cool side, and use a grill thermometer to monitor heat.

8. 8

   Place each sausage on the cool side of the grate, away from direct heat. Smoke for 30–35 minutes, using smoke wood (oak or hickory chips or chunks) sparingly — too much smoke creates a bitter crust. You're looking for a thin, mahogany-brown color. Use an instant-read thermometer inserted into the center of one sausage; it should read 160°F for food safety.

9. 9

   Once the sausages reach 160°F internally, move them directly over the coals or to a hot zone of the grill (medium-high heat). Sear each one for 1–2 minutes per side, turning carefully with tongs, until the casing blisters and chars slightly in spots — this gives you that authentic smoky-charred exterior that defines Texas barbecue sausage.

10. 10

    Transfer the sausages to a resting board or cutting board and let them rest for 5 minutes before serving — this allows the juices to redistribute. Slice and serve whole, or cut into 2-inch pieces. Pair with white bread, pickles, and onions, Texas-style.

Tools you’ll need

• large stainless steel bowl
• small mixing bowl
• freezer
• sausage stuffer (hand-crank or electric)
• sausage pricker or clean needle
• parchment paper
• sheet tray
• smoker or kettle grill
• instant-read thermometer
• grill thermometer
• drip pan
• tongs
• cutting board

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