The method is repeatable.
We have made 2 more 18-20 lb batches as of 9/23/18. Each is as good as the last and leaves more room for experimenting with the spices.
It is definitely better to do the low temp smoke on a calm day. I am still having a bit of temp control trouble if windy as the Heatermeter does not yet have a damper. The problem is if the temperature spikes a bit, more fat renders off. With more fat on the fire, the temperature spikes and so on. Better if it can be held low and slow or you are a better tender of the smoker than I. Batch 3 was spiking on smoker temperature and was pulled at 3 hours. Batch 4 was kept low and slow for 4.5 hours.
The slabs of skinless pork belly we have been buying at Costco are in the 9-10 pound range. To best fit for smoking , they are sliced into thirds. We use a Large Big Green Egg with the 3 tier rack as you can see below. This was taken at the start of the smoking process.
4.5 hours later with the smoker temp at 190F, the internal temp is between 150F and 154F and has been there for the last hour. This is now food safe and pasteurized.
Net step is to refrigerate overnight, slice, bag and freeze. Ready for frying and raiding by the kids.
Follow-up and pointers (1/5/21)
Since this original blog post we have done many more batches, usually with 2 pork belly slabs, totalling 19-30 lbs per batch. We have settled on using one of the refrigerator crisper drawers to hold the meat while it cures. Typically we cure for 10 days.
Be sure to let the meat come up to room temp prior to placing in the smoker. This helps further dry the outer layer and prevents soot from condensing on the bacon. Have the meat ready to go when lighting the BGE. It takes <10 min to get it going enough when using hardwood stick kindling (15 or so 1/4″ square x 4″ pieces). You DO NOT want it to overshoot the target temp as it can be very hard to bring it back down and you risk rendering the fat off the bacon and ending up with a out of control mess and the smoking fat adds a bitter flavor to the bacon.
205F seems to be the ideal temp in my BGE with the charcoal and woods I use, with the temp probe clipped to the top rack. Be SURE to close the top damper almost all of the way down EVERY time you open it or you risk run-away / out of control temps (yes this is from experience). Play with the temps on your setup anywhere form 185-225 to see what you like. 275 is definitely too hot and will start rendering fat off and feeding the fire.
For flavor, I still use a mix of cherry chunks or which I have an unending supply, but have also started supplementing with Traeger Signature pellet mix which also has Cherry, Hickory and Maple. About half and half seems to be the best flavor. Just heap the pellets on the charcoal near the center (about 1.5 cups). I had bought the pellets and a serpentine basket for cold smoking some ham.
Mark Bronkalla