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There are few things better than the smell of sausage and peppers grilling over an open flame. It instantly brings back memories of summer festivals and late-night pub crawls. But, while the classic sandwich is great, I wanted to elevate it to something truly special.
The secret to this version is utilizing the low-and-slow smoking capabilities of the Big Green Egg to get that perfectly rendered fat and deep, smoky flavor. Paired with high-quality Snake River Farms Hot Italian Kurobuta Sausage Links and a homemade pesto mayo, this recipe takes a backyard classic and pushes it over the top. It is complex, comforting, and absolutely delicious.
Now sit back, grab an ice-cold Peroni, and enjoy this recipe for the ultimate Big Green Egg Italian Sausage and Peppers Sandwich.
Table of Contents
- Step 1: Big Green Egg Setup
- Step 2: Prepping the Ingredients
- Step 3: Cooking the Peppers and Onions
- Step 4: Grilling the Sausages
- Step 5: Toasting the Rolls
- Step 6: Assembly and Melting the Cheese
- Step 7: Melting the Cheese
- Step 8: Final Assembly and Enjoying
- Big Green Egg Italian Sausage and Peppers Sandwich Recipe
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Step 1: Big Green Egg Setup
For this cook, I am using the MiniMax for its efficiency and heat control.
Set up your Big Green Egg for direct grilling and preheat it to 400°F. Getting the temperature stabilized early is key to perfectly cooked sausages.
Step 2: Prepping the Ingredients
While the Big Green Egg is preheating, let’s get the vegetables ready to go.
Slice 1/2 of a red onion, 1 yellow bell pepper, and 1 red bell pepper. Place them in a bowl, add 1 tablespoon of olive oil, and a few shakes of Dizzy Pig SPG seasoning (or your favorite salt, pepper, and garlic blend) to taste. Toss everything together until the vegetables are lightly coated.
Step 3: Cooking the Peppers and Onions
Using a cast iron pan inside the Egg gives the vegetables a great roasted flavor while keeping them moist.
When the Big Green Egg is coming up to temperature, place a 10.5″ cast iron pan inside to preheat.
Once the Egg is stabilized at 400°F, carefully add the seasoned onion and pepper mixture to the hot pan.
Saute for 5 to 10 minutes, stirring often, until the vegetables have developed some color and are nice and soft. Remove the cast iron pan and veggies from the Egg and set them to the side.
Step 4: Grilling the Sausages
Now it is time to cook the sausage links over that direct heat.
First, rub a little oil on the grill grate to prevent sticking before placing the sausage links on the grid.
For this cook, I am using Snake River Farms Kurobuta Hot Italian Sausage Links (they are incredibly flavorful), but any high-quality Italian sausage link will work perfectly here.
Cook the sausages for 10 minutes or so, turning often to ensure even browning. When they reach an internal temperature of 135°F, pull them off the Egg and set them aside.
Step 5: Toasting the Rolls
A perfectly toasted roll is crucial for holding up to all the toppings without getting soggy.
Take softened butter and rub it over the inside and outside of your sausage rolls.
Place the rolls directly on the Big Green Egg and toast for 1 to 2 minutes per side until golden brown.
When the rolls are toasted, remove them from the heat and set them aside.
Step 6: Assembly and Melting the Cheese
Now let’s bring it all together for that gooey, melted cheese finish.
Place the cooked sausage links back into the cast iron pan, covering them with the cooked onion and pepper mixture.
Top the mixture with 4 slices of provolone cheese.
Step 7: Melting the Cheese
Just a few more minutes until you can eat!
Place the cast iron pan back into the Big Green Egg for 5 minutes or so, or until the provolone cheese is perfectly melted and bubbly.
Making the Pesto Mayonnaise
Before you even start the Big Green Egg, it is best to prepare the sauce so the flavors have a chance to meld together.
In a small bowl, combine 3 tablespoons of your favorite basil pesto with 2 tablespoons of high-quality mayonnaise. Mix together thoroughly until completely combined and smooth.
For a deeper flavor profile, you can add a small squeeze of fresh lemon juice or a pinch of garlic powder, though the pesto generally provides all the flavor needed. Set this mixture aside in the refrigerator until you are ready to assemble the sandwiches.
Step 8: Final Assembly and Enjoying
It is time for the final assembly of your masterpiece.
Take your toasted bun and spread a generous amount of the homemade pesto mayonnaise on both the top and bottom.
Carefully place the hot, cheese-covered sausage and pepper mixture into the roll.
Take a big Buddha Bite and write me a thank you in the comment section below!
Final Thoughts
There you have it—a classic pub staple completely elevated by the flavor of the Big Green Egg. By taking the time to smoke the sausage and roast the peppers in a cast iron pan, you achieve a depth of flavor that a standard kitchen stove just cannot match.
The combination of the savory sausage, sweet roasted peppers, creamy provolone, and that bright pesto mayonnaise makes for a truly unforgettable bite. It is the perfect recipe for impressing friends and family at your next cookout.
Big Green Egg Italian Sausage and Peppers Sandwich
Equipment
- 1 Cast Iron Pan
Ingredients
Sausage & Peppers Ingredients:
- 1 package of Snake River Farms Hot Sausage Links or 8oz of hot sausage links
- 1/2 red onion, sliced
- 1 red bell pepper, sliced
- 1 yellow bell pepper, sliced
- 1 Tbsp olive oil
- 1 Tbsp Dizzy Pig SPG Seasoning
- 4 slices of provolone cheese
- 1 Tbsp butter, softened
- 2 sausage rolls
Pesto Mayonaise Ingredients:
- 3 Tbsp Pesto
- 2 Tbsp Mayonnaise
Instructions
- Preheat your Big Green Egg to 400°F set up for direct grilling. I am using the MiniMax for this cook. While the Big Green Egg is preheating slice 1/2 red onion, 1 yellow bell pepper, and 1 red bell pepper. Place in a bowl then add 1 Tbsp of olive oil and a few shakes of Dizzy Pig SPG seasoning.
- When the Big Green Egg is coming up to temp, place one of their 10.5″ Cast Iron Pans in to preheat. When the Big Green Egg is preheated to 400F place the seasoned onion and pepper mixture in the cast iron pan. Saute 5-10 minutes stirring often until the veggies have some color and are nice and soft. Remove the cast iron pan and veggies when done and set to the side.
- Make sure to rub oil on the grill grate before place the sausage links on. I am using Snake River Farms Kurobuta Hot Italian Sausage Links for this cook (so good). Cook the sausage for 10 minutes or so turning often. When they measure 135°F internal, pull and set to the side.
- Take softened butter and rub your sausage rolls inside and out. Place them on the Big Green Egg and toast each side for 1-2 minutes. When the rolls are toasted, remove and set aside.
- Next place the sausage links in the cast iron pan, cover with the onion peppers mix, and top with 4 slices of provolone cheese.
- Place back in the big green egg for 5 minutes or so until the cheese is melted. Remove and start to assemble your sandwiches.
- Before making your grilled sausage and peppers sandwich make a delicious pesto mayonnaise. Take 3 Tbsp of pesto and 2 Tbsp of mayonnaise and mix together.
- Now take your grilled bun, spread some of the pesto mayonnaise, and place the grilled sausage and peppers covered with cheese in to the roll. Take a big Buddha Bite and write me a thank you in the comment section below!
Nutrition information is automatically calculated, so should only be used as an approximation.
