Grilled Beef Brisket Sausage Hoagie Recipe

Prepare brisket

Trim any large chunks of gristle from the cooked brisket. Finely chop or pulse brisket in a food processor in short bursts until mixture is roughly medium-fine (not a paste). Place chopped meat in a large chilled bowl.

If using fat, finely dice and add to the chopped brisket. Keep ingredients cold — place bowl over an ice bath if your kitchen is warm.

In a small bowl combine kosher salt, black pepper, smoked paprika, garlic powder, onion powder and brown sugar. Sprinkle the seasoning mix over the chopped brisket and add Worcestershire sauce.

Add ice water to the meat mixture. Using a spoon or your hands, mix vigorously for 2–3 minutes until the meat is sticky and the ingredients bind. If you have a stand mixer with a paddle attachment, mix on low for 1–2 minutes to develop a cohesive texture.

If stuffing into casings: rinse casings under cool water and soak per package instructions. Fit a sausage stuffer or a piping bag with a wide tip to a funnel. Feed casings onto the stuffing tube and leave a tail. Fill casings with the brisket mixture, avoiding large air pockets. Twist sausages into 6–8 inch links. If not using casings, form mixture into 8 evenly sized logs (about 4–5 oz each) and wrap tightly in plastic for grilling (or use metal skewers). Chill sausages for 30–45 minutes to firm up.

Preheat grill to medium-high (about 375–400°F / 190–205°C). Oil grates lightly. Grill the sausages over indirect heat first for 6–8 minutes to gently cook through, turning occasionally, then move to direct heat to develop char and color for 2–4 minutes, turning so they brown evenly. Aim for internal temperature of 160°F (71°C) for safe reheated brisket-based sausage. If using a skillet, sear over medium-high heat 3–4 minutes per side, then reduce heat and cook through until 160°F.

Once cooked, remove sausages from the grill and let rest 5 minutes. If you formed logs without casings, keep them wrapped or on a plate while resting.

Lightly butter the inside of each hoagie roll. Place rolls cut-side down on the grill or in a skillet over medium heat and toast until golden, about 1–2 minutes. Remove and keep warm.

Slice each sausage lengthwise almost through (optional) or leave whole. Place a warm grilled brisket sausage into each toasted hoagie roll.

Top each sausage with a slice of provolone or cheddar so it slightly melts on the warm sausage. Add a spoonful of pickled jalapeños and pickled red onions to taste.

Add shredded lettuce and 2–3 tomato slices per hoagie. Drizzle 1/2 tablespoon yellow mustard and 1/2 tablespoon mayonnaise over toppings (adjust to taste).

Serve immediately while hot so cheese is melty and rolls remain crisp.