Smokey Bandit Patty Melt Recipe

Make aioli

In a small bowl combine mayonnaise, minced chipotle, smoked paprika, lime juice and honey. Stir until smooth and taste; adjust chipotle or honey to achieve desired heat/sweet balance. Refrigerate until assembly.

Measure out BBQ sauce into a small bowl for easy spreading during assembly.

Separate onion into thin rings and gently toss rings to loosen into strings. Pat dry if very wet.

In a shallow bowl whisk together flour, cornstarch, salt and pepper. Add cold sparkling water a little at a time until batter is smooth and slightly loose — it should lightly coat the onions.

Heat vegetable oil in a medium skillet or pot to 350°F (175°C) or until a small drop of batter sizzles and browns quickly. Working in batches, toss onion strings in the batter to coat, shake off excess, and fry until golden brown and crisp, about 1–2 minutes per batch. Use a slotted spoon to transfer to a paper towel–lined plate and season immediately with a pinch of salt.

Drain pickled jalapeños of excess liquid and set aside. Reserve about 2 tablespoons of the jalapeño slices for each sandwich (adjust to heat preference).

Divide the ground beef into 4 equal portions (about 4 oz each). Lightly form each portion into a loose ball — do not overwork the meat.

Heat a large heavy skillet or griddle over high heat until smoking-hot. Add neutral oil and spread to coat.

Place one or two balls of beef on the hot surface; immediately press down firmly with a flat spatula or dedicated smash press to create thin patties (~1/4 inch thick). Season the exposed surface with a light pinch of kosher salt and black pepper.

Cook the patties without moving for 2–3 minutes until deeply browned and edges are crisp. Flip, immediately place a slice of pepperjack cheese on each patty, and cook for another 45–60 seconds until cheese melts and interior reaches desired doneness. Repeat with remaining portions. Reduce heat slightly if cheese browns too fast.

Spread a thin layer of butter on one side of each sourdough slice. Heat a clean skillet over medium heat and toast the buttered side of bread slices until golden brown, about 1–2 minutes per side. For best results, toast one side, flip and toast the other just enough to create a firm slice that will support the sandwich.

Place two toasted sourdough slices, toasted-side up, on a clean work surface. Spread about 1 tablespoon of smokey aioli on each bottom slice.

Place a cheese-topped smash patty on each aioli-coated slice. Drizzle about 1 tablespoon of BBQ sauce over each patty (adjust to taste).

Top each patty with a generous pinch of crispy onion strings (about 2 tablespoons), and then arrange 2 tablespoons of pickled jalapeños over the onions for heat. If using, add a small piece of lettuce or pickle slices to preference.

Spread a thin layer of aioli on the inside of the remaining two toasted bread slices and place aioli-side down to cap each sandwich.

Press sandwiches gently to compact. If desired, return sandwiches to a hot skillet for 30–45 seconds per side to heat through and further meld flavors; watch carefully to avoid burning the bread.

Serve immediately with extra crispy onion strings and pickled jalapeños on the side.