Double Smoked Ham Big Green Egg Recipe: Smoky Cured Meat Meets Cast Iron Crispiness

This double smoked ham in a Big Green Egg transforms cured meat into a showstopping breakfast centerpiece with smoky depth and cast-iron crispiness. The key? Slow-cooking over indirect heat until the bark forms that perfect mahogany crust, while the interior stays juicy and tender. I’ve perfected this method after years of experimenting with different wood types and temperature profiles—this isn’t just breakfast, it’s an event.

The Big Green Egg’s cast-iron design is what makes this recipe shine, locking in moisture while creating that coveted crispy exterior. You’ll start with a dry brine overnight to enhance flavor penetration, then smoke the ham at 225°F until the internal temperature reaches 160°F. The secret? A mix of hickory and applewood chips for a balanced smoky-sweet profile that complements the ham’s natural sweetness.

What you’ll end up with is a ham that’s deeply caramelized on the outside, with a tender, juicy interior that slices effortlessly. The crust will be crackly and aromatic, while the meat retains its natural moisture—no dry, rubbery texture here. This isn’t just breakfast; it’s a weekend-worthy centerpiece that pairs perfectly with honey-glazed sweet potatoes or a fresh garden salad.

The best part? The Big Green Egg’s even heat distribution means you won’t waste time babysitting the ham—just set it, monitor the temperature, and let the smoker do the work. Whether you’re hosting brunch or treating yourself to a special morning, this recipe delivers restaurant-quality results with minimal effort. Let’s get started on creating that perfect smoked ham.

Ingredients for double smoked ham big green egg

Sixteen ingredients to transform ordinary ham into a smoky, crispy Big Green Egg masterpiece.

The ham is your canvas—bone-in, whole leg cuts from Hormel or Smithfield deliver the best texture. Look for hams with good marbling and minimal pre-curing; Butcher shops often carry superior quality over grocery store options. The wood chips are non-negotiable—Traeger brand chips are my go-to for consistency, but any food-grade chips work. The dry brine is where magic happens: overnight in the fridge with olive oil and salt ensures maximum flavor penetration. Pro tip: Use a meat thermometer to monitor internal temp—160°F is your sweet spot.

No hickory chips? Mesquite or pecan chips work in a pinch, though the flavor profile shifts. Swap applewood for cherrywood if you prefer fruitier notes. The spices are traditional but flexible—skip the cloves if you dislike their intensity. For a sweeter finish, boost the honey to 1/3 cup and reduce the brown sugar. Pre-cured hams? Skip the overnight brine but still apply the spice rub. The Big Green Egg’s cast iron means you can flip the ham halfway for even bark development—just watch those temps like a hawk.

This ham keeps beautifully—5 days refrigerated or 3 months frozen if wrapped tightly in butcher paper. The crust gets even better after resting 20 minutes post-smoke. For serving, I always slice it against the grain for maximum tenderness. Leftovers? Reheat in the oven at 325°F with a splash of water to revive the moisture. The glaze ingredients can be pre-mixed and stored in the fridge for 1 week—just whisk and warm before drizzling.

Step-by-step instructions for double smoked ham on Big Green Egg

Transform your Big Green Egg into a smoky ham haven with this foolproof method for crispy, flavorful results.

Start by combining the 0.5 cup kosher salt and 0.25 cup brown sugar in a bowl. This dry brine mixture is essential for creating that perfect balance of saltiness and subtle sweetness throughout the ham. Add the 1 tbsp black peppercorns, 1 tsp ground cloves, and 1 tsp mustard seeds to the mixture, then stir until thoroughly combined.

Next, crush the 4 whole garlic cloves lightly with the flat side of a knife to release their aromatic oils. Add them to the seasoning blend along with the 0.25 cup fresh rosemary and 0.25 cup fresh thyme, breaking the herbs into small sprigs. The combination of these spices and herbs will infuse the ham with layers of flavor that pair beautifully with the smoky notes from the Big Green Egg.

Pat the 8 lb bone-in ham completely dry with paper towels—this is crucial for achieving crispy skin. Using your hands, generously coat the ham with the seasoning mixture, pressing it into the meat so it adheres well. Pay special attention to the bone-in areas and the outer edges, as these tend to dry out first. Place the ham on a rack set over a baking sheet to allow air circulation on all sides.

Refrigerate the seasoned ham uncovered for 24 hours. This step is non-negotiable—it allows the dry brine to penetrate deeply, ensuring both flavor and moisture distribution. The longer it sits, the better the results, but 24 hours is ideal for a perfect balance of seasoning and texture. Real talk: Skipping this step will leave you with a ham that's either too salty on the outside or bland in the center.

Fill the charcoal ring with lump charcoal and ignite it using a chimney starter. Once the coals are covered with a thin layer of ash, distribute the 2 cups hickory wood chips and 1 cup applewood wood chips evenly over the coals. The combination of these woods will give you a rich, balanced smoky flavor—hickory for depth and applewood for subtle sweetness. Close the lid and let the wood chips smoke for 10 minutes to create a steady, clean smoke.

Place the Big Green Egg on a stable surface and open the lid. Position a drip pan in the bottom of the cooking chamber to catch any juices that render out during the smoking process. This prevents flare-ups and keeps your cooking area clean. Once the temperature stabilizes at 225°F, you're ready to smoke the ham. I press down gently on the lid to ensure a good seal—this helps maintain consistent temperature and smoke circulation.

Place the seasoned ham fat-side up on the grill grate. The fat will render slowly, basting the meat and creating that coveted crispy bark. Close the lid and smoke the ham for 6-8 hours, maintaining the temperature at 225°F. This low-and-slow approach ensures the meat cooks evenly and develops deep, smoky flavors without drying out. Here's the thing—resist the urge to open the lid. Every time you peek, you lose heat and extend the cooking time.

After 6-8 hours, check the internal temperature using a meat thermometer. The ham is ready when it reaches 160°F in the thickest part of the meat. At this point, the ham will have developed a beautiful mahogany bark and will be tender enough to pull apart with a fork. If the bark isn't as crispy as you'd like, you can increase the heat to 250°F for the last 30 minutes to intensify the color and texture.

While the ham rests, prepare the glaze by combining the 0.25 cup honey and 2 tbsp balsamic vinegar in a small saucepan. Warm the mixture over medium heat until it begins to bubble and thicken slightly, about 3-5 minutes. Stir in 2 tbsp olive oil to help the glaze cling to the ham. This glaze adds a beautiful sheen and a perfect balance of sweet and tangy flavors.

Brush the glaze generously over the ham, ensuring it coats all sides evenly. Return the ham to the Big Green Egg and cook for an additional 15-20 minutes over medium heat to caramelize the glaze. Watch closely—the glaze should darken and bubble, creating a sticky, glossy finish. Once the glaze is set and the ham reaches an internal temperature of 170°F, remove it from the grill and let it rest for 15 minutes before slicing. This resting period allows the juices to redistribute, ensuring every slice is moist and flavorful.

Troubleshooting great double smoked ham big green egg

Smoke Temp Fluctuations

If your Big Green Egg struggles to maintain 225°F, check for drafts near the lid or uneven charcoal distribution. I’ve found that placing a towel barrier around the lid seals gaps, while rearranging coals to form a ring of heat helps stabilize temps. Use a bi-metal thermometer like the ThermoWorks Smoke for accuracy—digital probes can lag behind actual temps. 🌡️

Bark Not Forming

For a stubbornly pale crust, try increasing heat to 250°F for the final 30 minutes while spraying the ham with apple cider vinegar every 10 minutes. The acid breaks down proteins, promoting browning. Alternatively, flip the ham halfway through cooking—fat-side down first to render, then fat-side up for bark development. A wire cooling rack under the ham elevates it for even airflow.

Uneven Cooking

If one side cooks faster, rotate the ham 90 degrees every 2 hours to prevent hot spots. The Big Green Egg’s dome shape can create temperature gradients—use a heat deflector plate (like a cast-iron skillet) to diffuse heat. For large hams, consider butterflying (slicing horizontally) to ensure even doneness, though this alters presentation. 🔥

Glaze Too Runny

Simmer your honey-balsamic glaze longer to thicken—5-7 minutes instead of 3-5. For extra cling, add 1 tsp cornstarch mixed with 1 tbsp water to the saucepan. If the glaze still pools, brush it on in thin layers, letting each coat set slightly before adding more. A pastry brush works better than a spoon for even distribution.

Dry, Stringy Meat

This usually means the ham cooked past 165°F or lacked moisture. Next time, wrap the ham in butcher paper (not foil) after 4 hours of smoking to trap steam. For pre-cured hams, reduce cooking time by 30-60 minutes—they’re already partially cooked. Always rest the ham 15 minutes before slicing to retain juices. A meat mallet can help tenderize if needed, but it’s a last resort.

Smoke Too Heavy

If your ham tastes like a campfire, adjust your wood-to-charcoal ratio. For every 10 lbs of charcoal, use 1 cup total wood chips (split 2:1 hickory to applewood). Let chips smoke for 10 minutes before adding meat to clear excess tar. A smoke tube inserted into the charcoal ring gives more control over smoke intensity. 🌳

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