Recipe Note
Recipe FAQ
Why cook at 450°F over direct flame instead of a lower temperature?
Pork tenderloin is a very lean, uniformly-shaped cut that benefits from a high-heat direct grill cook rather than low-and-slow smoking. At 450°F over direct flame, the exterior develops char and bark quickly while the center comes to 140–145°F without drying out — the cook is fast enough that the lean meat doesn't have time to lose moisture. A lower temperature would extend the cook time without producing the char that makes this recipe work.
What's the right internal temperature to pull the tenderloin?
140–145°F, as the recipe directs. The USDA revised its recommendation for whole cuts of pork from 160°F down to 145°F with a 3-minute rest in 2011 — at that temperature, pork tenderloin is slightly pink in the center, fully safe, and noticeably juicier than tenderloin cooked to 160°F. Carry-over heat during the 3–5 minute rest after pulling will bring it up a few more degrees. Use an instant-read thermometer; tenderloin is thin enough that visual cues are unreliable.
What are GrillGrates and why does the recipe call for them?
GrillGrate panels are reversible aluminum grill grates that sit over your existing grates. The raised rails concentrate heat and produce deeper sear marks, while the valley channels drippings away from the flame rather than flaring. Over the firebox on the YS640s at 450°F, they create an intense, even sear surface that produces the char on all four sides of the tenderloin that this recipe is built around. The flat side can also be used as a griddle surface. They're compatible with the YS640s and most pellet grills.
Can I substitute a different sauce for the Firebug Mild Grillin Sauce glaze?
Yes — any lightly sweetened, balanced BBQ sauce with enough sugar content to set as a glaze works. Avoid very thin or vinegar-heavy sauces, which won't cling to the hot tenderloin the way a thicker sauce does. The Firebug Mild is specifically calibrated to be flavorful without overpowering the Yardbird rub underneath — if you substitute, choose something similarly mild and sweet rather than a bold, smoky, or spicy sauce.
Can I cook these indoors?
Indoor cooking rating: 4 out of 5 — Great in the kitchen, better on the grill. A cast iron grill pan or skillet on a high-heat burner replicates the direct sear well indoors — get it smoking hot before the tenderloin goes in and turn every few minutes for even char on all sides. Finish in a 425°F oven if needed to reach 140–145°F internal. What you lose is the live-fire char character from the GrillGrates over the firebox and any ambient pellet smoke. The glaze-off-heat step works identically indoors.
Recipe Highlights
Remove the Silverskin Before Seasoning: Pork tenderloin has a thin, pearlescent membrane — the silverskin — running along one side. It doesn't break down during cooking and becomes tough and chewy in the finished tenderloin. Slide a sharp boning knife under one end of it, angle the blade slightly upward, and pull in one long strip. This takes 30 seconds and makes a meaningful difference in the eating experience, especially on a cut this small where every bite counts.
Slather Generously, Season Immediately After: The Blues Hog Honey Mustard needs to coat the entire surface of the tenderloin — not a thin wipe, but an actual slather. Apply the Plowboys Yardbird Rub immediately after while the mustard is still wet and tacky so it adheres rather than falling off during the sear. Let the seasoned tenderloin sit at room temperature for 5–10 minutes before it goes on the grill so the rub starts to dissolve into the mustard coating.
Turn for Char on All Sides, Not Just Two: Tenderloin is a tapered cylindrical cut — grilling it like a steak (two sides only) leaves the rounded edges pale and unseared. The directions call for turning to get char on all sides, which means rotating 90 degrees three or four times during the 15–20 minute cook. That full rotation produces a crust that's consistent around the entire exterior rather than just on the flat surfaces that happen to contact the grate.
Apply the Firebug Glaze the Moment It Comes Off: The window for applying the glaze is the 60–90 seconds immediately after the tenderloin comes off the grill. The surface is still above 140°F and the residual heat sets the glaze against the bark as it cools — by the time the tenderloin has rested 3–5 minutes, the glaze is adhered and slightly tacky rather than wet and runny. Apply too early (during cooking) and it burns; apply too late (after full rest) and it doesn't set properly.
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