Smoked Bologna Sandwich
This smoked bologna sandwich stacks thick slices of smoked bologna and melted American cheese on a mayo-toasted bun, finished with mustard and Blazing Star BBQ Spicy Sauce. A mustard binder, Pork’n Rub and a glaze of Original BBQ Sauce give the bologna a flavorful crust before it ever hits the bun.
It had been a while since I smoked a chub of bologna, but my brother inspired me to fire up the smoker again. For this cook, I used my Iron Oak BBQ Pits 115 offset smoker with Jealous Devil lump charcoal and Country Flame firewood. Simple ingredients, a little smoke and plenty of flavor. Oh Yeah!
Smoked Bologna Sandwich Recipe
| Prep Time | Cook Time | Estimated Yield | Difficulty |
|---|---|---|---|
| About 15 minutes | 3½ hours, plus cheese melting and bun toasting | 12–16 sandwiches | Easy |
Smoker temperature: 250°F
Equipment: Smoker, smoking wood or charcoal appropriate for your cooker, knife, cutting board, heat-safe rack, basting brush and a skillet or griddle for toasting buns.
Ingredients
For the Smoked Bologna
- 1 fully cooked bologna chub, approximately 4 pounds
- Yellow mustard, enough for a thin coating
- Blazing Star BBQ Pork’n Rub, enough to season the outside evenly
- Blazing Star BBQ Original Sauce, enough to glaze the outside
For Each Sandwich
- 1 sandwich bun
- 1 thick slice of smoked bologna, or more to your liking
- 2 slices American cheese per slice of bologna
- Mayonnaise, enough for a thin coating on the cut sides of the bun
- Yellow mustard, to taste
- Blazing Star BBQ Spicy Sauce, to taste
Prepare as many sandwiches as you need. The total yield depends on how thick you slice the bologna and how many slices you use per sandwich.
Make It With Pork’n Rub, Original and Spicy BBQ Sauce
Pork’n Rub seasons the outside of the bologna, Original BBQ Sauce creates the finishing glaze, and Spicy BBQ Sauce adds a kick to the assembled sandwich.
Shop Pork’n Rub | Shop Original BBQ Sauce | Shop Spicy BBQ Sauce
Veteran-owned flavor made for the grill, smoker and kitchen.
Instructions
- Preheat the smoker. Set up your smoker for indirect cooking at 250°F.
- Season the bologna. Remove all packaging and any inedible casing. Spread a thin coating of yellow mustard over the bologna, then season the outside evenly with Pork’n Rub.
- Smoke for 3 hours. Place the bologna on the smoker and cook at 250°F for approximately 3 hours.
- Glaze with Original BBQ Sauce. Brush the bologna with Original BBQ Sauce and smoke for another 30 minutes to let the glaze set.
- Slice and add cheese. Transfer the bologna to a cutting board and cut into thick slices. Place the slices you are serving on a heat-safe rack and top each with 2 slices of American cheese.
- Melt the cheese. Return the rack to the smoker until the cheese is melted.
- Toast the buns. Spread a thin layer of mayonnaise on the cut sides of the buns. Toast them cut-side down in a skillet or on a griddle until golden.
- Build the sandwiches. Add the cheesy smoked bologna to the toasted buns. Finish with yellow mustard and Spicy BBQ Sauce, then serve warm.
Pro Tips
- Use a whole bologna chub so you can smoke it first and cut thick sandwich slices afterward.
- A thin coating of mustard helps the seasoning stick.
- Add the Original BBQ Sauce during the final 30 minutes so the glaze has time to set.
- Melt the cheese only on the slices you plan to serve.
- Toast the buns just before assembling for the best texture.
Frequently Asked Questions
How long do you smoke a bologna chub at 250°F?
This recipe uses approximately 3 hours of smoking followed by another 30 minutes after adding the BBQ sauce glaze. Allow a little extra time to melt the cheese and toast the buns.
What kind of bologna should I use?
Use a whole, fully cooked bologna chub. This recipe is based on an approximately 4-pound chub. Remove all packaging and any inedible casing before seasoning.
Do I need an offset smoker?
No. I used an offset smoker for this cook, but you can use another smoker that maintains 250°F with indirect heat.
Why put mustard on the bologna before smoking?
The mustard acts as a binder to help Pork’n Rub stick to the outside of the bologna.
Can I make the sandwich less spicy?
Yes. Use Original BBQ Sauce on the finished sandwich in place of Spicy BBQ Sauce.
Shop the Flavors
- Shop Blazing Star BBQ Pork’n Rub
- Shop Blazing Star BBQ Original Sauce
- Shop Blazing Star BBQ Spicy Sauce
- Prefer Amazon? Shop Blazing Star BBQ on Amazon
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