Mustard-Crusted Smoked Deli Roast Beef

Recipe Notes

1. Temperature is everything.  Pull the roast at 130°F for perfect medium-rare. Do not go above 135°F because bottom round has very little fat and it will become dry and tough when sliced thin if overcooked.
2. Mustard is the binder and adds incredible flavor. Don't skimp on the mustard. 2–3 tablespoons gives you a thin, even coating that does double duty — it binds the dry rub to the meat AND contributes a subtle but noticeable tang that you'll taste in every bite.
3. Definitely use smoked paprika over regular. We tested this with smoked paprika instead of regular and won't go back. It deepens the wood-fired flavor in a way that makes the whole rub taste more intentional and cohesive.
4. Wood chip choice: Hickory gives a bold, classic smoky flavor. Pecan is milder and slightly sweet. Either works beautifully for beef.
5. Weston-specific instructions: The smoking instructions in this recipe are specific to the Weston 2-in-1 smoker in combo mode. If you're using a different smoker, follow your manufacturer's guidelines for setup and wood chip preparation.
6. Combo mode timing note: The Weston timer only adjusts in 30-minute increments. Set it for 120 minutes and start checking internal temperature around the 90-minute mark. The machine automatically transitions from cold smoke to heat on its own — no manual switching needed.
7. Cold overnight chill is the secret to deli-style slicing. Resting the roast is not optional, but the overnight chill is where the magic happens. Cold meat slices dramatically thinner and cleaner than warm meat. If you want true deli-style paper-thin slices, wrap it tightly and refrigerate overnight. Two hours is the minimum.
8. No meat slicer? A long thin slicing knife or electric carving knife works well on a thoroughly chilled roast. For even thinner slices, pop the wrapped roast in the freezer for 30 minutes before slicing to firm it up further.
9. Try it with stone ground mustard. Next time we make this we're swapping the yellow mustard for stone ground. The coarser texture should create an even more interesting crust and the flavor profile is a bit sharper and more complex. We'll update this recipe once we've tested it — if you try it before we do, let me know in the comments!
10. Beyond the sandwich — serving ideas:

• French dip with a twist — Warm slices in hot beef broth and use the liquid as your dipping jus. The mustard and smoke flavor makes this anything but ordinary.
• Classic deli sandwich — Piled high on a hearty roll with our roasted garlic & parmesan or dill pickle & whole grain mustard aioli.
• Roast beef hoagie — Toasted hoagie roll with provolone, sautéed peppers and onions. Open-faced roast beef — Thick-sliced sourdough with caramelized onion & blue cheese aioli and arugula.
• Roast beef wrap — Whole wheat tortilla with sharp cheddar, tomato, and smoked paprika aioli.
• Beef and cheddar style — Toasted brioche bun with sharp cheddar and honey chipotle aioli.