Smoked Sausage

1. 1
   prep

   Soak the wood chips and prepare the casings.

   Soak applewood chips in cold water for at least 1 hour. Meanwhile, soak hog casings in warm water for 30 minutes, then flush the insides with cool water and keep in a bowl of cool water until ready to use.

   TIPKeep the casings submerged in water so they stay pliable and easy to slide onto the stuffing tube.
2. 2
   mix

   Combine the dry spices.

   In a small bowl, mix together the salt, curing salt, black pepper, garlic powder, onion powder, smoked paprika, chili powder, and brown sugar until evenly combined.

3. 3
   prep

   Grind the meat and fat.

   Pass the partially frozen pork shoulder and fatback through the grinder fitted with a medium die. Work in small batches and keep everything cold — if the meat starts to smear or feel tacky, pause and chill for 10 minutes.

   TIPCold meat = clean grind. Put grinder parts in the freezer for 20 minutes before starting.
4. 4
   mix

   Mix the sausage farce.

   Add the spice blend and the ice-cold water to the ground meat mixture. Mix vigorously with your hands (wear gloves) or a paddle attachment for 2-3 minutes until the farce turns tacky and starts to bind — you should see white strands forming when you pull it apart.

   TIPTake a small spoonful and fry it in a pan to check the seasoning. Adjust salt or spices now before stuffing.
5. 5
   assemble

   Stuff the sausages.

   Slide the soaked casing onto the stuffing tube, leaving about 4 inches hanging off the end. Load the farce into the stuffer and fill the casings firmly but not so tight that they burst. As the casing fills, guide it off the tube and coil the sausage onto a tray.

   TIPDon't tie off the end until air is pushed out — let the farce push out any air pocket first, then tie the end.
6. 6
   assemble

   Form links and prick air pockets.

   Twist the stuffed coil into 4 equal links, alternating the direction of each twist so they hold. Use a clean pin or sausage pricker to poke any visible air bubbles under the casing, then place the links on a wire rack set over a sheet tray.

   TIPPricking prevents the casings from bursting when they hit the heat.
7. 7
   rest

   Rest the links uncovered in the fridge.

   Place the tray of sausages in the refrigerator, uncovered, for at least 2 hours (or up to overnight). This dries the casings slightly and helps the pellicle form, which smoke clings to.

   TIPA dry, slightly tacky surface is what smoke adheres to — don't skip this rest.
8. 8
   roast

   Smoke the sausages low and slow.

   Fire up your smoker to 165°F (74°C). Drain the wood chips and add to the smoker. Hang the sausage links on hooks or lay them on a greased grate so they don't touch. Smoke for 60-70 minutes with the vent open — you want steady thin blue smoke, not billowing white clouds. The sausages should take on a deep reddish-brown hue.

   TIPThin blue smoke = clean flavor. Billowing white smoke tastes acrid and bitter — adjust your vents or wood quantity if needed.
9. 9
   roast

   Finish cooking to internal temperature.

   Raise the smoker temperature to 225°F (107°C) and continue cooking until the internal temperature of the sausages reaches 152°F (67°C) on an instant-read thermometer, about 25-35 minutes more.

   TIPPull them between 150-155°F — carryover cooking will bring them to the safe 160°F as they rest.
10. 10
    rest

    Bloom the sausages at room temperature.

    Remove the sausages from the smoker and let them rest on a wire rack at room temperature for 15 minutes. The color will darken and deepen as they cool — this is called blooming and gives them that classic smoked sausage look.

    TIPDon't cover them while resting or you'll trap steam and soften the snap of the casing.
11. 11
    serve

    Slice and serve, or chill for later.

    Slice the links diagonally and serve warm with mustard and pickles. Or cool completely, wrap tightly, and refrigerate for up to 5 days. For longer storage, vacuum-seal and freeze for up to 3 months.

    TIPSmoked sausages are fully cooked. For serving, just reheat gently on a grill or in a skillet with a splash of water — no need to cook again.

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