Homemade Smoked Pastrami Reuben

Make homemade pastrami from scratch with a simple curing brine, a bold coriander and black pepper bark, and a low-and-slow smoke. Slice it thin and pile it onto rye bread with homemade Russian dressing, sauerkraut and melted Swiss cheese for the ultimate BBQ Reuben.

This is the full BBQ LAB method, from curing the beef through to smoking, slicing and building the Reuben.

Recipe Information

Prep Time: 30 minutes
Curing Time: 7–10 days
Drying Time: Overnight
Smoking Time: 10–12 hours
Smoker Temperature: 250°F / 120°C
Serves: Depends on the final cooked weight

How many people does it serve?

The easiest way to work this out is based on the final cooked weight of your pastrami.

For example, if you finish with 3kg of pastrami and use approximately 200g per Reuben, you'll get:

3,000g ÷ 200g = 15 generous sandwiches

Adjust the amount per sandwich depending on how heavily you like to load your Reuben.

Ingredients

Pastrami Brine

The brine is calculated based on the weight of the water, not the weight of the meat.

• Water — enough to completely submerge your beef
• Pink curing salt
• Kosher salt
• Sugar
• Black peppercorns
• Bay leaves
• 1 large beef brisket or other large cut of beef

Brine Formula

Calculate each ingredient from the weight of your water:

• Pink curing salt: water weight × 0.25%
• Kosher salt: water weight × 6%
• Sugar: water weight × 3%

For example, for 1kg of water:

• 2.5g pink curing salt
• 60g kosher salt
• 30g sugar
• 1 tbsp whole black peppercorns
• 3–4 bay leaves

The peppercorns and bay leaves are for flavour and aren't included in the percentage calculations.

Important: Pink curing salt means a curing salt containing sodium nitrite — it is not Himalayan pink salt. Check the concentration of the product you're using and follow the manufacturer's directions. Accurately weigh curing salt and don't substitute Cure #2 or another curing product.

Pastrami Rub

You have two options.

Option 1 — Classic Pastrami

• Coarse coriander
• Coarse black pepper
• Garlic powder
• Onion powder

Use coarse coriander, not coriander powder.

Option 2 — BBQ LAB Black Gold

• 50% BBQ LAB Black Gold
• 50% coriander, black pepper and garlic seasoning

Black Gold brings its coffee and peanut butter flavours into the bark, giving the pastrami a deeper, richer BBQ flavour while still keeping the classic coriander and pepper character.

Russian Dressing

• 120g mayonnaise
• 40g ketchup
• 20g finely chopped dill pickles or pickle relish
• 1 tsp prepared horseradish
• 1 tsp Worcestershire sauce
• ½ tsp smoked paprika
• ½ tsp garlic powder
• ½ tsp onion powder
• Pinch of salt
• Freshly cracked black pepper

For the Reuben

• Homemade smoked pastrami
• Rye bread
• Sauerkraut
• Swiss cheese
• Homemade Russian dressing
• Butter, for toasting
• Pickles, to serve

Method

1. Prepare the curing brine

First, work out how much water you need to completely submerge your brisket.

Weigh the water and calculate the curing ingredients from that weight.

For every 1kg of water, use:

• 2.5g pink curing salt
• 60g kosher salt
• 30g sugar

Add the black peppercorns and bay leaves.

Mix thoroughly until the salt and sugar have dissolved.

Make sure the brine is completely chilled before adding the beef.

2. Cure the beef

Place your brisket, or whatever large cut of beef you're using, into the chilled brine.

For an easy option, use a BBQ LAB Heavy Duty Brining Bag to hold the meat and brine securely.

Make sure the beef is completely surrounded by the brine and keep it refrigerated throughout the curing process.

Leave the beef in the brine for approximately 7–10 days, depending on the size and thickness of the cut.

The thicker the piece of meat, the longer it will take for the cure to penetrate all the way through.

3. Rinse and dry the beef

Once the beef has finished curing, remove it from the brine.

Give it a thorough rinse under cold water to remove the excess brine and surface salt.

Pat the beef completely dry with paper towel.

4. Apply the pastrami rub

Now it's time to build the bark.

Classic Pastrami

Generously coat the beef with:

• Coarse coriander
• Coarse black pepper
• Garlic powder
• Onion powder

Make sure you're using coarse coriander rather than coriander powder. The larger pieces give you that classic pastrami texture and help create a fantastic crust.

BBQ LAB Black Gold

Alternatively, use 50% BBQ LAB Black Gold and 50% coriander, black pepper and garlic seasoning.

The coffee and peanut butter flavours from Black Gold add a rich, savoury depth to the bark while the coriander and black pepper keep the flavour recognisably pastrami.

5. Rest overnight

Place the seasoned beef on a rack and leave it uncovered in the refrigerator overnight.

This gives the seasoning time to adhere to the meat and helps dry the surface, which will give you a better bark during the cook.

6. Smoke the pastrami

The next day, fire up your smoker and bring it to:

250°F / 120°C

Place the beef into the smoker and cook it low and slow.

Smoking time will generally be around 10–12 hours, depending on the size and thickness of your brisket.

Cook until the brisket has pushed through the stall and reaches approximately 160–170°F internal temperature, or until you've developed the dark, well-formed bark you're looking for.

The bark is more important than hitting an exact internal temperature at this stage.

7. Wrap in butcher paper

Once you're happy with the bark, wrap the pastrami tightly in butcher paper.

Return it to the smoker at 250°F.

Continue cooking until it reaches around:

202°F / 94°C

But don't treat 202°F as a magic number.

The real test is probe tenderness.

Pastrami won't probe like traditional brisket

This is important if you're used to cooking brisket.

Your pastrami won't necessarily feel like a traditional brisket or pulled pork when it's finished.

Because the meat has been cured, the texture naturally firms up.

You're not looking for that same butter-like probe you might chase with a traditional brisket.

You want it tender enough to slice cleanly while still retaining some structure.

Don't keep cooking it simply because it doesn't feel exactly like a normal brisket.

8. Rest the pastrami

Once the pastrami is cooked and tender, you've got two options.

For hot pastrami

If you're going to eat it warm, allow it to cool slightly and slice it when the internal temperature is around 150°F.

This gives you juicy, tender slices while the meat is still warm.

For cold pastrami

If you're making this for sandwiches, this is my preferred method.

Wrap the cooked pastrami tightly in cling film and place it in the fridge overnight.

The following day, slice the pastrami while it's cold.

The chilled meat firms up considerably, allowing you to get much cleaner and thinner slices.

9. Make the Russian dressing

Add the mayonnaise, ketchup, chopped pickles, horseradish, Worcestershire sauce, smoked paprika, garlic powder and onion powder to a bowl.

Season with a little salt and freshly cracked black pepper.

Mix everything together until smooth and evenly combined.

Taste and adjust to your liking.

For a sharper dressing, add a little more horseradish or pickle. For a sweeter dressing, add a little more ketchup.

Cover and refrigerate until you're ready to build the sandwiches.

10. Slice the pastrami

Once the pastrami is cold, slice it as thinly as possible.

A meat slicer is ideal, but a sharp knife will work.

The cold meat will allow you to get much thinner and cleaner slices than slicing it hot.

Build the Reuben

11. Assemble the sandwich

Spread a generous amount of homemade Russian dressing onto two slices of rye bread.

Pile on plenty of your thinly sliced pastrami.

Add a good layer of sauerkraut.

Top with Swiss cheese.

Finish with the second slice of rye bread.

12. Toast the Reuben

Butter the outside of the rye bread.

Place the sandwich onto a hot pan or griddle.

Cook until the bread is golden and crisp and the Swiss cheese has completely melted.

Give it a gentle press as it cooks to bring everything together.

Slice in half and serve immediately with a pickle.

BBQ LAB Tips

Use coarse coriander

Don't use coriander powder. Coarse coriander gives you the texture and appearance you want from a traditional pastrami crust.

Give the cure enough time

The 7–10 day curing period is a guide. The thicker your brisket, the longer it will take for the cure to penetrate.

Use a brining bag

A large brisket can be awkward to brine in a container. A dedicated brining bag makes the process much easier.

Rinse after curing

Give the beef a thorough rinse to remove excess brine and surface salt before seasoning.

Dry it overnight

Leaving the seasoned beef uncovered in the fridge overnight helps dry the surface and gives the seasoning time to adhere.

Chase the bark

At around 160–170°F, you're looking for a dark, well-developed bark. Once it's there, wrap it.

Don't chase the brisket probe

Pastrami is cured, so its texture is naturally firmer. Don't expect it to probe like a traditional brisket.

Cold pastrami slices better

If you're making Reubens, chill the pastrami overnight and slice it cold. You'll get considerably cleaner and thinner slices.

Work out servings by weight

If you finish with 3kg of pastrami and use 200g per Reuben, that's approximately 15 sandwiches.

Frequently Asked Questions

How long should you cure beef for pastrami?

For this method, cure the beef for approximately 7–10 days, depending on the size and thickness of the cut.

What temperature do you smoke pastrami at?

Smoke homemade pastrami at 250°F / 120°C.

How long does it take to smoke pastrami?

Allow approximately 10–12 hours, depending on the size and thickness of your brisket. Cook according to the bark, internal temperature and tenderness rather than time alone.

When should you wrap pastrami?

Wrap the pastrami once you've developed a dark, well-formed bark, generally around 160–170°F internal temperature.

What temperature is pastrami done?

Aim for approximately 202°F / 94°C, but use probe tenderness as your final test.

Why doesn't pastrami probe like brisket?

Curing changes the texture of the beef. Pastrami naturally has a firmer structure, so it won't necessarily develop the same soft, buttery texture as a traditional smoked brisket.

Can you eat pastrami hot?

Yes. If you're serving it warm, slice the pastrami at approximately 150°F.

Is pastrami better hot or cold?

Both are great. Hot pastrami is juicy and tender, while cold pastrami is firmer and much easier to slice thinly. For Reubens, chilling it overnight gives you the cleanest slices.

What seasoning is best for pastrami?

Classic pastrami is fantastic with coarse coriander, coarse black pepper, garlic powder and onion powder. For a BBQ LAB twist, use 50% Black Gold and 50% coriander, black pepper and garlic seasoning.

What cheese goes on a Reuben?

Swiss cheese is the classic choice. Its nutty flavour and excellent melting qualities work perfectly with pastrami and sauerkraut.

What bread is used for a Reuben?

Rye bread is traditionally used. Its earthy, slightly sour flavour works particularly well with rich pastrami, Swiss cheese, sauerkraut and Russian dressing.