Homemade Smoked Chilli Smash Burger
Smash burgers topped with a smoked beef and beer chilli, cooked on the BBQ. A messy, meaty burger with a slow-cooked chilli kick.

Ingredients
- Beer Chili (Smoker Method)
- Beef mince (80/20): 1kg
- Brown onion, diced: 1 large
- Red chillies, diced: 4 long
- Green chillies, diced: 4 long
- Minced garlic: 1 tbsp
- Olive oil: 1 tbsp
- Chopped tomatoes (canned): 400g
- Tomato puree (canned): 400g
- 4 bean mix or kidney beans (canned): 400g
- Cocoa powder: 2 tbsp
- Powdered chili: 2 tsp
- Chili flakes: ½ tbsp
- Beef stock: 1 litre
- Stout beer: 1 can
- Salt & pepper: to taste
- Smash Burgers
- Beef mince (high-fat): 4 × 100g balls
- Salt: to taste
- Cracked black pepper: to taste
- American cheese slices (or high-melt burger cheese): 4 slices
- Brioche or potato buns: 4
- Butter (for toasting buns): as needed
- Optional Toppings
- Pickles: sliced
- Jalapeños: sliced
- Onion rings: cooked
- Mayo or chipotle mayo: to taste
Method
Set Up the BBQ: Light your Heat Beads Lump Charcoal and place two half-moon baskets full of lit coals in the centre of the Weber for direct cooking. Keep the bottom vent fully open. Preheat a heavy cast iron pan directly over the beads.
Make the Beer Chili: Add the olive oil to the pan. Add diced onion and cook until soft and translucent. Add the red and green chillies, and cook until fragrant. Add garlic, then the beef mince. Brown thoroughly, breaking into small bits. Add chopped tomatoes, puree, and beans. Stir to combine. Mix in the cocoa powder, powdered chili, and chili flakes. Pour in 1 cup of beef stock and stir well. Move charcoal baskets to the sides for indirect cooking and place the pan in the center of the grill grate. Close the bottom vent halfway, lid on, top vent fully open. As it smokes, top up with beef stock in 1 cup increments as it evaporates. After 45 minutes, pour in one can of beer or stout, stir, and continue to simmer until rich and thick (roughly 1.5 hours total). Season to taste.
Smash the Burgers: Move to the hot side of the BBQ. Place a flat top or cast iron griddle over direct heat. Add beef balls and smash hard with a spatula. Season with salt and pepper. When juices bubble and edges are crispy, flip and immediately top with a cheese slice. Let the second side sear while cheese melts.
Build the Burger: Toast buns in butter until golden and crisp. Place each cheesy smash patty on the bottom bun. Spoon a generous scoop of the beer chili over each. Add desired toppings: pickles, jalapeños, onion rings, mayo. Cap with top bun.
Serve: Serve hot with plenty of napkins. Expect melty cheese, crispy beef edges, and a smoky, boozy chili that makes this burger next-level messy and delicious.
Best fuel for a quick grill
Our Pitmaster’s Pick, plus two great alternatives.
Based on Heat Beads® testing. Burn times vary with fuel, BBQ and weather.
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