Ingredients:

  • 1 (2.5–3 lb / 1.15–1.4 kg) Beef Tri-Tip Roast
  • 2 Tbsp (30 ml) Olive Oil or Yellow Mustard (as a binder)
  • 2 Tbsp (30 ml) Kosher Salt
  • 1 Tbsp (15 ml) Coarse Ground Black Pepper
  • 1 Tbsp (15 ml) Dark Brown Sugar (packed)
  • 1 Tbsp (15 ml) Smoked Paprika
  • 1 Tbsp (15 ml) Chili Powder (Ancho or standard blend)
  • 1 Tbsp (15 ml) Finely Ground Coffee (dark roast preferred)
  • 1 tsp (5 ml) Garlic Powder
  • 1 tsp (5 ml) Onion Powder
  • ½ tsp (2.5 ml) Cayenne Pepper (optional, for heat)

Instructions:

  1. Trim the Tri-Tip: If untrimmed, remove the thickest layers of silver skin and excess fat. Pat the entire roast bone dry with paper towels.
  2. Make the Rub: In a small bowl, thoroughly combine all ingredients listed under 'The Robust Coffee-Chili Rub'.
  3. Apply the Binder and Rub: Lightly coat the Tri-Tip with the olive oil or mustard binder. Generously and evenly apply the rub mixture to all surfaces, pressing gently to create a thick, consistent layer (the bark).
  4. Cure (Crucial Step): Place the rubbed Tri-Tip on a wire rack over a baking sheet, uncovered. Refrigerate for at least 2 hours, or ideally 4 to 12 hours. This drying process enhances smoke penetration and bark formation.
  5. Preheat the Grill (Smoke Setting): Set the pellet grill to the lowest smoke setting, usually between 180°F–225°F (82°C–107°C). Allow it 15–20 minutes to stabilize and produce clean smoke.
  6. Smoke the Beef: Insert a digital meat probe into the thickest part of the roast, avoiding the fat cap or bone. Place the Tri-Tip directly on the grill grates. Smoke until the internal temperature reaches 125°F (52°C) for medium-rare.
  7. Remove and Prepare for Sear: Once the target temperature is reached, immediately remove the Tri-Tip from the grill and tent loosely with foil.
  8. Increase Grill Temperature: Crank the pellet grill temperature up as high as it will go (ideally 450°F / 230°C or higher). Allow 10–15 minutes for the grill to fully heat.
  9. Sear the Beef: Place the Tri-Tip back on the hottest part of the grill. Sear for 4–6 minutes per side, turning once. The goal is a deep, dark brown crust (the bark).
  10. Check Final Temperature: Pull the Tri-Tip when the internal temperature hits 130°F–135°F (54°C–57°C).
  11. Rest (Mandatory): Transfer the finished Tri-Tip to a cutting board. Tent loosely with foil and allow it to rest for a full 15 minutes. This retains the juices.
  12. Slice Correctly: Tri-Tip has two distinct grain directions. Identify where the grains shift and slice the meat thinly (no more than ¼ inch / 6 mm thick), ensuring you slice against the grain in both sections. Serve immediately.