Smoked and Seared Bologna Sandwich

Jump to recipe

This Smoked Bologna Sandwich transforms a humble deli meat into a bold BBQ centerpiece using the Masterbuilt Gravity Series® Grill and Smoker. Scored, seasoned, smoked low and slow with hickory, then seared and topped with melty provolone, this sandwich packs smoky, tangy, cheesy flavor in every bite. Add mayo, mustard, juicy tomato, and a toasted bun—BBQ nostalgia just got an upgrade.

Pro Tips

  • Want to go full Southern? Swap provolone for pimento cheese.

  • Add extra kick with hot mustard or pickled jalapeños.

  • Use the Gravity Series®' precise temp control to keep the bologna juicy while creating that perfect bark.

Why the Gravity Series® is Perfect for This

The Masterbuilt Gravity Series® Digital Charcoal Grill and Smoker allows you to set and hold low temps like 275°F for extended smokes, while still delivering searing heat when it’s time to melt cheese or toast buns. With charcoal flavor and digital convenience, this grill makes classic smoked sandwiches easier—and tastier—than ever.

McLemore Boys

Smoked and Seared Bologna Sandwich

Serves: 8 people
Skill:
Beginner

Ingredients

  • Main

Instructions

  1. 01

    Preheat your Gravity Series® grill to 275°F, loading hickory chunks into the hopper or directly onto the charcoal for rich, bold smoke.

  2. 02

    Score the bologna log into a 1-inch checkerboard pattern, slicing about ¼-inch deep. This helps the seasoning penetrate and creates crispy bark.

  3. 03

    Rub the bologna with yellow mustard, then coat liberally with BBQ seasoning. Place on the middle rack of your grill over indirect heat and smoke for 4 hours until a bark forms and the edges crisp up.

  4. 04

    Remove the bologna and cut into 8 thick slices along the scored lines. Top each with 2 slices of provolone and return them to the grill until the cheese melts (about 2–3 minutes).

  5. 05

    Toast the buns on the grill. Spread with mayonnaise and/or mustard, then stack with sliced tomato, cheesy smoked bologna, and extra cheese if you're feeling it. Slice in half and serve warm.

MASTER IT.

There's an app for that.

Masterbuilt Recipes

Craft a Masterpiece

View All Recipes