Smoked Sausage Recipe

Prep sausages

Remove sausages from refrigerator 20 minutes before smoking so they come closer to room temperature. Pat dry with paper towel. Lightly score (1/8" shallow diagonal cuts) the casing on each sausage every 1 inch to encourage even smoking and a crisp snap.

Season and apply binder

Brush each sausage lightly with yellow mustard to help smoke and spices adhere. Sprinkle evenly with kosher salt and freshly ground black pepper on all sides.

Prepare smoker

Preheat smoker to a steady 225°F (107°C). If using a charcoal or pellet grill, set up for indirect low heat. Drain soaked applewood chips and place on coals or in a smoker box so they generate smoke steadily.

Smoke sausages

Place sausages on the smoker grates leaving space between each for smoke circulation. Smoke at 225°F for 45–60 minutes until internal temperature reaches 150–155°F (65–68°C). Aim for a light golden-brown exterior with a visible smoky ring just beneath the surface. Rotate sausages once after 25–30 minutes for even color.

Optional finishing sear

If you want a crisper casing, transfer sausages to a hot skillet or grill set to medium-high for 1–2 minutes per side after smoking, creating a quick sear and audible snap. Do not overcook — target final internal temperature of 160°F (71°C).

Rest

Remove sausages and rest on a cutting board for 5 minutes to let juices redistribute. Slice lengthwise or diagonally into 1/2" slices depending on presentation.

Toast buns

Split brioche buns. Spread about 1/2 teaspoon of softened butter inside each bun. Toast cut sides on a hot griddle or skillet over medium heat 1–2 minutes until golden and lightly crisp. Keep warm.

Assemble

Place a smoked sausage (whole or sliced) into each toasted brioche bun. Layer optional sweet onion slices and pickled jalapeño slices to taste. If serving 'dry', leave off the sauce. For sauced, see sauce directions and spoon 1–2 tablespoons of sauce over each sausage.

Combine and simmer

In a small saucepan combine ketchup, apple cider vinegar, brown sugar, Worcestershire sauce, smoked paprika, garlic powder, onion powder, hot sauce (if using), salt, and black pepper. Whisk to combine.

Cook

Bring sauce to a low simmer over medium-low heat. Cook uncovered, stirring occasionally, for 8–10 minutes until slightly thickened and glossy. Taste and adjust seasoning: add more brown sugar to sweeten, more vinegar for tang, or a pinch more smoked paprika for smokiness.

Cool and store

Remove from heat and let cool slightly. Spoon into a jar and keep warm until serving. Leftover sauce stores refrigerated up to 1 week.