Beer Chicken Sando Recipe

Prepare marinade and marinate

In a shallow dish or resealable bag, combine beer, olive oil, minced garlic, brown sugar, smoked paprika, dried oregano, kosher salt, and black pepper. Whisk or shake to combine. Add chicken thighs, pressing to coat. Marinate in the refrigerator for at least 30 minutes and up to 4 hours. (Do not exceed 8 hours to avoid texture issues from the beer.)

Preheat oven and roast

Preheat oven to 425°F (220°C). Line a rimmed baking sheet with foil and place a wire rack on top if available. Remove chicken from marinade, letting excess drip off, and arrange on the rack. Roast for 12–16 minutes, flipping once halfway through, until internal temperature reaches 165°F (74°C) and edges are lightly browned. For a bit of char, broil 1–2 minutes at the end watching carefully.

Rest and slice

Transfer roasted chicken to a cutting board and let rest 5 minutes. Slice each thigh into 3–4 pieces or leave whole depending on sandwich size.

While the chicken roasts, make the aioli. In a small bowl whisk together mayonnaise, minced chipotle in adobo, lime juice, honey, grated garlic, and salt until smooth. Taste and adjust heat or sweetness—add more chipotle for spice or a little extra honey to balance. Refrigerate until ready to assemble.

Toast buns

Spread softened butter on cut sides of the buns. Heat a large skillet over medium heat. Toast buns buttered-side down 1–2 minutes until golden and crisp. Remove from heat.

Assemble sandwiches

Spread about 1 tablespoon of chipotle aioli on the bottom half of each bun. Place a portion of roasted chicken on top, then add a slice of muenster cheese (or two halves to cover) while the chicken is still warm so the cheese softens. Top with 1 leaf of green leaf lettuce and about 2 tablespoons of butter pickles. Finish with the bun top and press gently.

Serve

Serve immediately while warm. Optionally cut sandwiches in half and serve with fries or a simple slaw.