The Texas Lesson: It's All About the Casing
If you've been tossing sausages on the grill or smoker and calling it a day, there's a good chance you've been doing it wrong—at least according to Texas pitmasters. The good news? The fix is simple and will completely change the way you cook sausage forever.
During a trip to Texas, James Mack—better known as Smoking Dad BBQ—got a behind-the-scenes look at how some of the best pitmasters in the country prepare smoked sausage. While his ribs and brisket earned top marks, the biggest lesson he brought home wasn't about meat—it was about mastering the casing.
Let's break down how to go from "good enough" sausage to Texas-style perfection with just a few extra steps on your Masterbuilt Gravity Series XT (or any smoker or charcoal grill).
While his ribs and brisket earned top marks, the biggest lesson he brought home wasn't about meat—it was about mastering the casing.
The Common Mistake: Cooking Too Hot and Too Fast
Most backyard cooks fire up their grill, cook sausage until it hits a food-safe temperature, and call it done. While that makes the inside safe to eat, it completely neglects the casing—the outer layer that gives sausage its iconic snap.
When the casing and filling don't cook evenly, you end up with:
- Shriveled, rubbery skins
- Exploded casings (and lost juiciness)
- Dry texture inside and out
The trick? Respect the casing as much as the filling. That means cooking lower and slower, and adding one critical (and often overlooked) step—the ice bath.
The Texas Technique: Three Steps to Perfect Sausage
According to Texas pitmasters (and confirmed by Michelin-recognized spots like Interstellar BBQ), great sausage isn't rushed. It's done in three deliberate phases:
Step 1: Cold Smoke
Start by "cold smoking" your sausage—though technically, this isn't true cold smoking since your smoker will run around 160–180°F.
- Fire up your Gravity Series XT with a small charcoal bed and add wood splits (white oak is a great choice).
- Keep temps low and steady for 1.5–2 hours, until the sausage hits about 150–155°F internal temperature.
- Maintain airflow and spacing to prevent "smoke bald spots" where the sausages touch.
This step builds deep flavor while gently rendering the fat inside without causing flare-ups or bursting.
Step 2: Ice Bath & Rest
Once your sausages reach temp, it's time for the game-changing move: the ice bath.
- Drop the sausages into an ice bath for about 15 minutes.
- Pat them dry, then place them on a drying rack in the fridge for at least 30 minutes (or overnight if you've got time).
This halts the cooking process immediately, locks in moisture, and tightens the casing for that crisp, satisfying snap when you bite in.
Step 3: Hot Smoke
Now, the fun part—bringing them back to life.
- Raise your grill temp to 225–250°F.
- Return the sausages to the smoker until they reach 155°F internal temperature again.
This final cook rewarms and finishes them off without overcooking. The result? A perfectly smoked sausage that's juicy inside, snappy outside, and full of bold smoke flavor.
