Grilled Italian Sausage and Peppers Sandwich on the Big Green Egg

Few things evoke summer better than the smell of sausage and peppers over an open flame. It brings back memories of festivals and backyard gatherings. This version elevates the classic sandwich by using the low-and-slow heat and smoky character of the Big Green Egg, paired with quality Italian sausage and a bright pesto mayonnaise.

Using the Big Green Egg to roast peppers and smoke the sausages gives deeply rendered fat and a smoky profile you can’t get on a stovetop. High-quality Hot Italian sausage and a simple homemade pesto mayo finish the sandwich with layers of flavor: savory meat, sweet roasted peppers, gooey provolone, and a herb-forward spread.

Relax with a cold beer and follow along to make the ultimate Big Green Egg Italian Sausage and Peppers Sandwich.

Step 1: Big Green Egg Setup

For this cook I use the MiniMax for its quick heat-up and control. Set the Big Green Egg for direct grilling and preheat to 400°F. Stabilizing the temperature early helps the sausages cook evenly and develop good color.

Step 2: Prepping the Ingredients

While the Egg is warming, prepare the vegetables. Slice 1/2 a red onion, 1 yellow bell pepper, and 1 red bell pepper. Toss them in a bowl with 1 tablespoon olive oil and a pinch of salt, pepper, and garlic or your favorite seasoning until evenly coated.

Step 3: Cooking the Peppers and Onions

A preheated cast iron pan in the Egg gives the vegetables a roasted, slightly caramelized flavor while keeping them tender. When the Egg reaches 400°F, place a 10.5″ cast iron pan inside to heat. Add the seasoned peppers and onions and sauté for 5–10 minutes, stirring frequently, until they have color and are soft. Remove the pan and set the vegetables aside.

Step 4: Grilling the Sausages

Lightly oil the grill grate to prevent sticking, then place the sausage links directly on the grid. I prefer Kurobuta or other high-quality Hot Italian links for their flavor, but any good Italian sausage will work. Grill, turning often, for about 10 minutes until evenly browned. Pull them when they reach approximately 135°F internal and let them rest briefly.

Step 5: Toasting the Rolls

A sturdy, toasted roll keeps the sandwich from getting soggy. Rub softened butter on both the inside and outside of each roll. Toast them directly on the Egg for 1–2 minutes per side until golden and crisp. Remove and set aside.

Step 6: Assembly and Melting the Cheese

Place the cooked sausages in the cast iron pan, top with the roasted peppers and onions, and cover with provolone slices—about four slices works well for two sandwiches.

Step 7: Melting the Cheese

Return the cast iron pan to the Egg for about 5 minutes or until the provolone has melted and is bubbly. Then remove the pan for assembly.

Making the Pesto Mayonnaise

Prepare the pesto mayo before you start cooking so the flavors meld. In a small bowl, combine 3 tablespoons basil pesto with 2 tablespoons mayonnaise and stir until smooth. Optional: add a squeeze of lemon or a pinch of garlic powder for extra brightness. Chill until ready to use.

Step 8: Final Assembly and Enjoying

Spread a generous amount of pesto mayonnaise on both halves of each toasted roll. Place the hot, cheese-covered sausages and peppers into the roll, close, and serve immediately. The combination of smoky sausage, sweet roasted peppers, melted provolone, and herbaceous pesto mayo is bold and balanced.

Final Thoughts

This elevated pub classic benefits from the Big Green Egg’s ability to add smoke and roast ingredients in cast iron. The result is a sandwich with depth and balance: savory, smoky sausage; sweet, roasted peppers; melty provolone; and a fresh pesto mayo brightening every bite. It’s an impressive, crowd-pleasing recipe for your next cookout.