Homemade Portuguese Chouriço

September 3, 2025 by Kathleen

- These smoking instructions are for use with an electric or gas smoker. Keep in mind that the directions for your smoker may differ.
- Preheat the smoker to 100°F (38°C) to 110 °F (43°C).
- Add the sausages, leave the damper open and the door slightly ajar, and maintain this temperature until the casings are dry to the touch, about 1 hour.
- Close the smoker door, then increase the temperature setting to 130°F (54°C), building the temperature slowly. The sausages will not smoke properly if the exterior is still moist, if the heat is too hot too soon, or if the process is rushed; they are more likely to steam. Slow smoking makes a more tender sausage.

When the internal temperature of the sausage reaches 100°F (38°C), increase the temperature setting to 150°F (66°C), then close the damper halfway.
After the casings are brown, add a pan of dampened (not soaking) sawdust; close the damper so it is only one-quarter of the way open.
When the amount of smoke from the damper decreases, add another pan of dampened sawdust. Repeat two or three times more, for a total of four or five times. Remove the pan completely when the sausage color is dark.
If the sausages have not reached an internal temperature of 125°F (52°C) at this point, adjust the temperature setting of the smoker to 160°F (71°C) to 165°F (74°C) and continue to smoke the sausages until they reach 125°F (52°C).
Continue to smoke the sausages until an internal temperature of 152°F (67°C) is reached. To reach the final internal temperature of the sausages, it may be necessary to fill the empty sawdust pan with boiling water and place it in the smoker.
Remove the sausages from the smoker. Rinse with cool water, reducing the internal temperature to 100°F (38°C). Hang the sausages on wooden dowels to dry for 20 to 25 minutes; the sausages will darken – or bloom – as they dry.
When completely cool, cover with wax paper and refrigerate. They will keep for up to 2 weeks, well wrapped. You can also place individually wrapped sausages in freezer bags and freeze until needed.