Grilled Smoked Sausage Recipe

Make the mustard barbecue sauce

In a small saucepan or skillet over medium-low heat, combine yellow mustard, brown sugar, apple cider vinegar, honey, ketchup, Worcestershire sauce, smoked paprika, onion powder, garlic powder, hot sauce (if using), salt, and black pepper. Whisk together until smooth.

Bring sauce to a gentle simmer, stirring frequently. Simmer for 4–6 minutes to thicken slightly and let flavors meld. Taste and adjust seasoning (more honey for sweetness, more vinegar for tang, or more hot sauce for heat). Remove from heat and set aside, keeping warm.

If you prefer a smoother, glossy sauce for tossing, simmer an additional 2–3 minutes; for a chunkier rustic sauce, remove as soon as it thickens slightly.

Preheat a charcoal or gas grill to medium-high (about 400–450°F / 200–230°C). If using a grill pan or skillet, heat over medium-high on the stovetop.

Trim sausages if needed and, optionally, slice each link in half lengthwise or into 1–1.5 inch diagonal pieces for more surface area and easier serving at a party.

Brush the grill grates lightly with oil or spray with nonstick before placing sausages to prevent sticking.

Place whole or cut sausages on the hot grill. Cook 4–5 minutes per side for whole links (or 3–4 minutes per side for cut pieces), turning every 3–4 minutes to develop even grill marks and an internal temperature of 160°F (71°C) for pre-smoked sausages or per label instructions. Aim for a nicely browned, slightly charred exterior without burning.

If sausages begin to brown too quickly, move them to a cooler part of the grill and close the lid to finish cooking through.

When sausages are cooked through, transfer them to a large mixing bowl or a shallow baking dish.

Pour about 3/4 of the warm mustard barbecue sauce over the sausages (reserve remaining sauce for serving). Gently toss with tongs or a spatula until sausages are evenly coated. For a glazed finish, return sausages to the grill for 1–2 minutes per side after saucing, watching closely so the sugars do not burn.

Add the unsalted butter to the warm sauced sausages and toss once more; the butter adds shine and richness.

Transfer sauced sausages to a serving platter. Spoon reserved sauce into a small bowl for guests to serve themselves.

Sprinkle chopped parsley and/or green onions over the sausages for color and freshness. Serve hot with toothpicks, slider rolls, or alongside sides like coleslaw and pickles.