Roasting a whole hog, step by step | Food Production and Preservation | Forums

OK, so I can't figure out how to post individual photos, so will have to do some homework. Here is the Flikr link of the event:

I've been roasting whole hogs in different ways for about 15 years, mostly at family BBQ's, graduations etc. Nothing professional whatsoever. I've learned something new each time I've done it, and by no means is it a perfected technique. Different methods I've done are the Kahlua Hawaiian style (buried pig wrapped in laa laa leaves), Spit roasted (manual) and modified chinese/cuban box style.

There are pro's & cons of each style. Kahlua is by far the easiest to do, but doesn't give you the variety of flavors/textures. Spit roasting manually is extremely time consuming, using a powered rotisserie is much easier, but the hardware is very expensive ($1500 for anything over 75 lbs.) The chinese box is a good method, but doesn't give the smoke flavor that I like.

My goal is to keep the method cheap, primitive and simple. For this, I've gone with the improvised chinese/cuban box technique, and here are some pictures of the process I use:

Tools & Materials list:

For the cooking box itself

48 Cinder blocks (the cheapest you can get)

1 roll of Costco Aluminum Foil

1 Roll stainless steel welding wire

Pliers

4 pairs work gloves

1/8 cord hardwood firewood

1 bag charcoal

Soaked smoking chips (mesquite, cedar, apple etc.)

Steel Frame (custom build)

Saw Horses

For Food Prep

8 Foot folding table

Table Cloths

Large cookie sheets & metal bins for processing

Multiple cutting boards & knives

Multiple Meat Thermometers (I use digital probe style, and had friend loan me an I/R surface analyzer for this one.)

Food Handlers gloves

The Pig

Between 60 & 150 lbs whole hog.

Salt

Dry Rub Seasoning

Canola Oil

The Brine

Apple juice

Vegetable stock

Onions

Garlic

Salt (about 3/4 lbs for every gallon of liquid brine)

Selection of the butcher/whole hog is important. If you go directly to a butcher, it will most likely come completely cleaned, de-haired and pretty much ready to go. There will be no organ meats unless specifically requested (this is easiest.)

If you want to go very rustic, you can go to a farm, and hand manage the process from there. Believe me, de-hairing a whole hog is very labor intensive, and you'll need some friends who are not afraid of working for their BBQ to get it done. If you know how to prepare organ meats, it's pretty amazing the variety of different dishes you can make (rustic sausages, soups, scrapple etc.)

Fist steps, build the oven

The oven starts with assembling the cinder blocks, and lining the inside with aluminum foil. As you can see in the photos, it's all dry assembly with no mortar etc. The frame we mount the pig on is a steel lattice constructed of welded bars of stock steel that I store with cooking oil so it doesn't rust. I bind the pig in with stainless steel welding wire, which you will notice as the webbing on the frame.

Next step, Brine it

Mix the brine in 5 gallon buckets and approximate the garlic and onions you throw in. I typically brine the pigs for 48 hours inside a marine cooler, but this particular pig was 140 lbs, and wouldn't quite fit. We fashioned an impromptu brine bucket by chopping up two plastic bins and duct taping them together, then using a huge food service freezer bag to wrap the pig in. If you are brining for multiple days, you have to make sure you keep the temp of the brine down at a steady, cool temp around 40 Fahrenheit, do not let it fluxuate, or it can introduce a more bacteria friendly environment. Low, cool & steady on the brine process is the motto.

Next Step, Mount the pig & season it.

Yes, it's heavy. It takes on weight in the brining process, so I suspect it was 160 lbs when we mounted it. Get a friend to help. It's best to let it dry out for a while to make sure some of the excess moisture drains off. Not taking this step can lead to premature carmelization of apple juice in the brine, or in the runoff of your dry rub. This pig was done with a garlic & onion rub, with salt added separately. I use a bit of oil to help it stick on the skin side. We add the 2nd lattice to the top & secure the two frames together with wire. o