If you've ever wanted a burger with the crackling, caramelized crust of a smash burger and the deep wood-smoke flavor of a low-and-slow BBQ cook — this is it. The method is simple: sear the patty ripping hot in a cast iron skillet over live coals, then move it to the smoker to finish at 225°F. Two stages, one incredible burger. The live-fire sear locks in a dark crust before the smoke has its way with the rest of the cook. Once you try it, you'll never go back to cooking burgers any other way.

Ingredients

The Burger

• 2Thick burger patties, 80/20 ground beef
• To tasteBeef BBQ rub (coarse black pepper and salt works great)
• 2 slicesAmerican or cheddar cheese
• 2Brioche buns, buttered and toasted
• As desiredToppings: lettuce, tomato, pickles, onion, sauce

Equipment

• 1Cast iron skillet
• 1Instant-read meat thermometer
• 1Offset smoker or charcoal grill with firebox access

Instructions

1. Set up your smoker for two-stage cooking. You need two heat zones: a ripping-hot coal bed in the firebox for searing, and a stable 225°F smoking chamber for the finish. Get the main chamber locked in at temperature first, then build your searing coal bed. For wood choice, post oak delivers a clean, medium smoke. Hickory or mesquite will push it heavier — your call.
2. Form and season the patties. Shape your 80/20 beef into thick pucks — don't go thin here, you need the mass to survive the two-stage cook with juice to spare. Season both sides generously with your beef rub. Let them sit at room temperature while the smoker comes up to heat.
3. Get the cast iron screaming hot. Set a dry cast iron skillet directly on the coal bed in the firebox. No oil, no butter — you're dry searing. Give it time to really heat up. You're targeting 600–700°F. A drop of water should vaporize instantly before the pan is ready.
4. Sear the patties. Lay the patties in the dry skillet and don't touch them. Sear for exactly 90 seconds. Flip once and sear another 90 seconds on the second side. You're building a dark, crackling crust — leave the lid open so the heat stays focused. Pull them out and take a look at that color.
5. Move to the smoker and finish low. Transfer the seared patties into the main smoking chamber at 225°F. Close the lid. The lower the temperature you smoke at, the more smoke the meat absorbs — 225°F gives you maximum smoke flavor. If you're pressed for time, 275°F still delivers great results.
6. Cook to your preferred doneness. Use an instant-read thermometer to check internal temperature. The USDA recommends 160°F for ground beef. Pull earlier if you prefer a pinker center — 145–150°F for medium, 155°F for medium-well. Know your preference and cook to it.
7. Melt the cheese. When the patties are 3–5 degrees away from your target temp, lay a slice of cheese on each one and close the lid for 2–3 minutes until fully melted.
8. Build and serve. Pull the burgers off the smoker and load them into the toasted brioche buns. Pile on your toppings and eat immediately — these are at their best right off the grill.