Overview

Smoke the lean brisket flat low and slow, then finish with a short, ripping-hot sear to lock in a dark, flavorful crust without drying the meat. This walkthrough focuses on precise temps, clean fire, and safe handling for repeatable results.

Ingredients

• 1 whole brisket flat, 5–8 lb (2.3–3.6 kg)
• Kosher salt at 1.5% of meat weight (about 34–54 g; ~2–3.5 Tbsp Diamond Crystal or 1–2 Tbsp Morton for 5–8 lb)
• 16-mesh black pepper, equal to the salt by weight (34–54 g)
• Optional: granulated garlic at 0.5% of meat weight (about 11–18 g)
• Yellow mustard binder, 1–2 Tbsp (15–30 g)
• Beef tallow or neutral oil for searing, ~1 Tbsp (15 g)

Equipment

• Offset, kettle, or pellet smoker capable of steady 225–250°F (107–121°C)
• High-heat sear setup: lump charcoal bed, Santa Maria grate, or cast-iron plancha
• Instant-read thermometer and leave-in probe(s)
• Unwaxed butcher paper or heavy-duty foil
• Wire rack and sheet pan
• Long tongs and high-heat gloves
• Sharp slicing knife and cutting board
• Water pan and spray bottle (optional)

Wood

Post oak (Texas-style)

Time & Temp

Time & Temp
Smoke temp: 235 °F (113 °C)
Target internal: 202 °F (94 °C)
Approx duration: 7.5 hours

Why Reverse Sear a Brisket Flat?

The flat is lean, cooks faster than a whole packer, and can dry out if you chase bark too long at the end. Reverse searing gives you the classic Texas bark by smoking first for tenderness and smoke uptake, then searing briefly at very high heat to harden the exterior without pushing the interior past ideal doneness.

Sourcing and Trimming the Flat

Choose a whole flat in the 5–8 lb range (2.3–3.6 kg), USDA Choice or Prime if possible for extra intramuscular fat. Look for even thickness and a flexible feel. Trim the fat cap to about 1/4 in (6 mm), remove hard surface fat and thin silverskin, and square ragged edges so they don’t overcook. Keep the cap where it best shields the flat from your pit’s heat source.

Seasoning Strategy (Texas Dalmatian)

A simple, sugar-free rub holds up to the sear. Use kosher salt at 1.5% of meat weight and equal black pepper by weight; optionally add 0.5% granulated garlic. Lightly coat the flat with yellow mustard as a binder, then season all sides evenly. Place on a wire rack over a sheet pan, uncovered, and dry-brine in the fridge at 34–38°F (1–3°C) for at least 4 hours and up to overnight.

Fire Management and Wood Choice

Run a clean, steady fire at 225–250°F (107–121°C) with thin blue smoke. Post oak is the Texas standard; white oak or a touch of hickory also works. On offsets, aim the fat cap toward the firebox side; on kettles or pellet grills where heat comes from below, go cap-down to protect the lean. Use a water pan if your cooker runs dry, but keep airflow clean so the bark doesn’t soften.

The Low-and-Slow Phase

Set the flat on the pit cold to maximize smoke adhesion and stabilize at about 235°F (113°C). Let it ride until color deepens and the surface turns from tacky to set, typically around 2–3 hours. If the surface looks parched before the bark sets, a light spritz of water or low-sodium beef stock is fine—keep it minimal to avoid washing off rub. Expect the stall near 160–170°F internal (71–77°C).

Wrap and Render: Managing the Stall

When the bark is set and internal reads roughly 165–170°F (74–77°C), wrap tightly in unwaxed butcher paper for a drier bark, or foil for a faster push at the cost of a softer exterior. Continue cooking at 225–250°F (107–121°C) until the flat reaches 190–195°F (88–91°C). At this point it should be close, but not fully probe-tender—perfect for a post-smoke rest and sear finish.

The Rest Before the Sear

Vent steam briefly by cracking the wrap, then re-wrap and rest the brisket on a wire rack so air can circulate. Let the internal temperature drift down into the 160–170°F (71–77°C) range for 30–60 minutes. This equalizes heat, relaxes the surface moisture, and prevents the sear from blowing past target doneness. Meanwhile, build a sear zone at 550–600°F (288–315°C) over lump charcoal, a plancha, or cast iron.

The High-Heat Sear

Unwrap and pat the surface dry. Lightly brush beef tallow or neutral oil on the bark. Sear fat side first directly over the hot zone for 60–90 seconds, then flip and sear the meat side for another 60–90 seconds; roll the edges briefly to even the crust. Avoid sugar in the rub and watch for flare-ups—move as needed to the cool side. The internal should climb into 200–203°F (93–95°C). If you’re short of temp, finish indirectly at 300°F (149°C) for a few minutes rather than extending the direct sear.

Doneness Checks and Slicing

Probe multiple spots; it should slide in like warm butter with minimal resistance. After searing, rest 15–30 minutes until the internal drops to about 150–160°F (66–71°C) so juices settle. Slice across the grain at about 1/4 in (6 mm); adjust thickness thinner if very tender, slightly thicker if on the firmer side. A good slice should bend and gently crack without crumbling.

Food Safety and Holding

Keep raw beef separate from ready-to-eat foods and sanitize tools and surfaces after trimming. During the cook, keep the pit above 225°F (107°C) and avoid extended time in the danger zone. If you need to hold after searing, keep the wrapped brisket above 140°F (60°C) in a warm oven or insulated cooler. Chill leftovers within 2 hours, store at or below 40°F (4°C), and eat within 3–4 days. Reheat slices to 165°F (74°C). Use high-heat gloves and long tongs around the sear zone to avoid burns and flare-ups.

Troubleshooting and Variations

If bark is already very dark before the wrap, lower pit temp to 225°F (107°C) and shorten the final sear to 30–45 seconds per side. If the flat is thin, favor 225°F (107°C) for the smoke to protect moisture. Pellet grill without a strong sear? Use a preheated cast-iron griddle or a chimney of lump with a small grate. Too salty? Drop salt to 1.2% next time. Prefer more smoke? Stay unwrapped longer but monitor color closely to avoid drying the edges.

Notes

• Pull from the smoker around 190–195°F (88–91°C); the sear will carry you into 200–203°F (93–95°C).
• Aim the fat cap toward your heat source to shield the flat.
• Keep rub sugar-free; sugar scorches at sear temps.
• Butcher paper preserves bark texture better than foil, which softens it.
• If internal temp rises too fast during the sear, move to indirect heat to finish.
• Hold finished brisket above 140°F (60°C) if delaying service; chill leftovers within 2 hours.