Name: Grilled Kentucky Hot Brown on the Big Green Egg
Prep time: 15 min
Cook time: 15 min
Total time: 30 min
Ingredients: 1 tbsp butter; 1 tbsp all-purpose flour; 1 cup 2% milk; 1/4 tsp black pepper; 1/8 tsp salt; 1/4 cup grated fresh Parmigiano-Reggiano cheese; 1 pound bacon (thick cut); 1/2 cup brown sugar; 1/2 tsp black pepper; 1/2 tsp cayenne pepper; 1/4 cup maple syrup; 2 pounds turkey breasts (skinless & boneless); salt & Pepper (to taste); 2 large tomatoes (cut into wedges); 2 tbsp olive oil; 4 slices Italian bread (thick cut); salt & Pepper (for seasoning the bread and tomatoes)

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If there is one dish that feels made for Kentucky Derby season, it is this Grilled Kentucky Hot Brown on the Big Green Egg. Loaded with smoked turkey, crispy bacon, fresh tomato, and rich Mornay sauce, this open-faced sandwich is pure comfort food with a serious upgrade from the grill.

The original Kentucky Hot Brown is a Louisville classic, and my wife grew up with this dish as part of that Kentucky tradition. It is one of those recipes that feels special every time it hits the table. Rich, messy, and absolutely worth it. Taking that same idea to the Big Green Egg adds even more flavor and turns a classic into something even better.

The live fire gives the turkey a little extra smoke, crisps the bread perfectly, and helps the entire dish come together with that backyard cooking flavor you just cannot get from the oven alone. Whether you are serving this for Derby Day, weekend brunch, or a casual dinner with friends, it is one of those recipes people remember. It looks impressive, tastes incredible, and is much easier to make than most people think.

Grilled Kentucky Hot Brown on the Big Green Egg

Preparing the Turkey
Making the Pig Candy Bacon
Grilling the Tomatoes and Bread
Making the Mornay Sauce
Assembling the Kentucky Hot Brown
Grilled Kentucky Hot Brown on the Big Green Egg Recipe

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Preparing the Turkey

Since I did not have leftover turkey on hand, I picked up a couple of boneless turkey breasts for this recipe. They work perfectly for a Kentucky Hot Brown and give you that same classic flavor without needing holiday leftovers.

First, I kept the seasoning simple with kosher salt and black pepper. You do not need much here because the rich Mornay sauce, crispy bacon, and fresh tomato bring plenty of flavor to the final dish.

For the best texture, I used sous vide to cook the turkey first. This keeps the meat tender, juicy, and perfectly cooked from edge to edge, which is exactly what you want when slicing turkey for sandwiches. After seasoning, I vacuum sealed the turkey breasts and dropped them into a 140°F water bath for 2½ hours. This gentle cooking method locks in moisture and gives you tender turkey without the risk of drying it out.

Once the sous vide cook was finished, I moved the turkey to the Big Green Egg to add a light smoky flavor and a little color on the outside. This gives you the best of both worlds… perfectly cooked turkey from the sous vide and that unmistakable live-fire flavor from the grill. Finally, let the turkey rest before slicing it thin for the Hot Brown.

Making the Pig Candy Bacon

A Kentucky Hot Brown is not complete without great bacon, and for this version I went with pig candy. Sweet, smoky, crispy bacon takes this sandwich to another level and adds the perfect contrast to the rich Mornay sauce.

First, set up your Big Green Egg for indirect cooking at 300°F. While the grill comes to temperature, mix the brown sugar, black pepper, and cayenne pepper in a small bowl. This simple combination gives the bacon a sweet start with just enough heat on the finish. Next, coat the thick-cut bacon slices evenly with the sugar mixture. Be generous here because the sugar will caramelize as it cooks and create that sticky, glossy finish everyone loves.

Then, place the bacon on a cooking rack and transfer it to the grill. Let it cook for about 30 to 40 minutes, depending on thickness, until the bacon is crisp and beautifully caramelized. During the last 5 minutes of cooking, brush the bacon lightly with maple syrup. This adds one final layer of flavor and helps create that classic pig candy finish. Once done, let the bacon cool slightly before adding it to the sandwich. Crispy, sweet bacon is one of the best parts of a great Kentucky Hot Brown.

Grilling the Tomatoes and Bread

After finishing the pig candy bacon, I increased the Big Green Egg temperature to 350°F for grilling the tomatoes and bread. This slightly higher heat helps the tomatoes soften quickly and gives the bread the perfect toasted finish.

First, I tossed the tomato wedges with a little olive oil, kosher salt, and black pepper. Keeping the seasoning simple lets the natural sweetness of the tomatoes shine once they hit the grill. Then, I took thick slices of Italian bread and lightly brushed both sides with melted butter. I also added a little salt and black pepper for extra flavor. The bread needs enough structure to hold the turkey, sauce, and bacon, so thick slices work best here.

Once the Egg was stabilized at 350°F, I placed both the tomatoes and bread directly on the grate for a quick direct cook. The tomatoes only need a few minutes to soften slightly and pick up a little char without falling apart. At the same time, the bread toasts beautifully and gets those perfect grill marks while staying sturdy enough for the open-faced sandwich. That little bit of grilled flavor makes the final Kentucky Hot Brown even better.

Making the Mornay Sauce

Now it is time for the part that makes a Kentucky Hot Brown truly special—the rich, creamy Mornay sauce. This cheesy sauce ties the entire sandwich together and gives the Hot Brown its signature flavor.

First, melt 1 tablespoon of butter in a medium saucepan over medium heat. Once melted, add 1 tablespoon of all-purpose flour and whisk well to form a smooth roux. This is the base that helps thicken the sauce. Next, gradually pour in 1 cup of 2% milk while whisking constantly. Then, add the black pepper and salt. Keep whisking so the sauce stays smooth and does not develop lumps.

Continue cooking over medium heat for about 5 minutes, stirring often, until the sauce thickens enough to coat the back of a spoon. You want it rich and creamy, but still pourable enough to spread over the sandwich.

Finally, remove the saucepan from the heat and stir in the freshly grated Parmigiano-Reggiano cheese. The cheese melts into the sauce and gives it that classic Mornay flavor that makes the Kentucky Hot Brown so good. This is not the place to rush. A smooth, silky sauce is what takes this sandwich from good to unforgettable.

Assembling the Kentucky Hot Brown

Once everything was ready, it was time to build the sandwich. At this point, I closed all the vents on the Big Green Egg so I was no longer cooking with active direct heat. The goal here is gentle residual heat to warm everything through and let the Mornay sauce finish without burning.

First, I assembled the open-faced sandwiches in a cast iron pan using the grilled Italian bread as the base. Then, I layered on the sliced turkey and grilled tomato wedges. Next, I poured the warm Mornay sauce generously over the top of each sandwich. Do not hold back here. The sauce is what makes a Kentucky Hot Brown, and you want every bite covered in that rich, cheesy goodness.

Then, I placed the cast iron pan back into the Big Green Egg and let it cook for about 10 to 15 minutes. The sauce should become hot, bubbly, and lightly browned on top while the bread soaks up all that flavor underneath. Finally, I topped each sandwich with the pig candy bacon and served everything right in the cast iron pan. It looks great, stays hot longer, and feels exactly like the kind of comfort food a proper Hot Brown should be.