Smoked cheddar jalapeño stuffed burgers take 2 lbs of 85/15 ground beef mixed with diced jalapeños, diced sweet onion, and cubed cheddar cheese directly into the meat, formed into 1/2-pound patties, seasoned with your favorite burger seasoning, and smoked at 250°F until they hit 165°F internal. The cheddar cubes melt into gooey pockets throughout the patty during the low-and-slow cook, and the jalapeños and onion soften and release their flavor into the beef from the inside out. American cheese goes on top during the last few minutes for a melted cap, and the whole thing gets built on toasted brioche buns with spicy mayo. Makes 4 burgers.

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Why Mixing the Fillings Into the Meat Works Better Than Stuffing

Cheddar, Jalapeño, and Onion in Every Bite

Traditional stuffed burgers hide a pocket of cheese in the center, which means you get one concentrated burst of filling when you bite into the middle and plain beef everywhere else. Mixing the cubed cheddar, diced jalapeños, and diced onion directly into the ground beef distributes the fillings throughout the entire patty. Every single bite has a melted cheese pocket, a piece of softened jalapeño, and a sweet onion hit. There are no dead spots of plain beef anywhere in the burger.

Cubed Cheddar Creates Melted Pockets

Cutting the cheddar into small cubes instead of shredding it is deliberate. Cubes hold their shape during the initial mixing and forming, then melt into distinct gooey pockets during the low-and-slow smoke. Shredded cheese melts too quickly and disperses into the beef in a thin, almost invisible layer. Cubes give you visible, defined cheese pockets that you can see when you cut the burger in half, and each one delivers a concentrated burst of melted cheddar when you bite through it.

Mixing and Forming the Patties

Combine Gently, Season Generously

In a large bowl, combine the ground beef, diced jalapeños, diced sweet onion, and cubed cheddar. Mix everything together until evenly distributed, but do not overwork the meat. Overhandling ground beef compresses the proteins and squeezes out moisture, which produces a dense, dry burger instead of a tender, juicy one. You can also add extra seasoning directly into the mixture before forming the patties if you want the spices worked through the interior of the beef.

Half-Pound Patties for a Substantial Burger

Form the mixture into 4 large patties, about 1/2 pound each. Since these patties are loaded with fillings, they need to be substantial enough to hold together during the smoke without falling apart on the grate. Season both sides generously with your favorite burger seasoning before they go on the smoker. The exterior seasoning creates a crust on the surface that complements the jalapeño, onion, and cheddar flavors coming from the interior.

Smoking at 250°F for Juicy, Melted-Through Results

Low and Slow Melts the Cheese Gently

Smoking the patties at 250°F instead of grilling over high heat gives the cheddar cubes time to melt slowly and evenly throughout the burger without the exterior burning or drying out. High heat would sear the outside and set the crust before the cheese inside has time to fully soften, leaving you with partially melted cubes in a well-done shell. At 250°F, the fat in the 85/15 beef renders gradually, the cheese melts into gooey pockets, and the jalapeños and onion soften completely by the time the interior reaches temperature.

Pull at 165°F with American Cheese on Top

Cook the burgers on the smoker until the internal temperature reaches 165°F, which ensures the ground beef mixture is fully cooked and safe. During the last few minutes of cooking, top each patty with a slice of American cheese and close the lid so the trapped heat melts the cheese into a smooth, creamy cap over the top. The American cheese on the outside complements the cheddar pockets on the inside, giving you two different cheese textures in every bite.

Assembly on Toasted Brioche with Spicy Mayo

Toast the Buns, Build the Burger

Toast the brioche buns on the grill or griddle until the cut sides are golden brown and slightly crispy. Spread spicy mayo on both the top and bottom bun. Place the smoked, cheese-topped patty on the bottom bun and serve immediately while the cheese is still melted and the jalapeño-studded interior is hot. The spicy mayo adds a creamy heat that builds on the fresh jalapeño flavor inside the patty.

Step-by-Step: How to Make Smoked Cheddar Jalapeño Stuffed Burgers

Step 1: Mix the Filling Into the Beef

In a large bowl, combine 2 lbs 85/15 ground beef, 2 diced jalapeños, 1/4 diced sweet onion, and 1/2 lb cubed cheddar cheese. Mix gently until the fillings are evenly distributed throughout the beef. Add extra seasoning directly into the mixture if you want the spices worked through the interior. Do not overwork the meat.

Step 2: Form and Season the Patties

Form the mixture into 4 large patties, about 1/2 pound each. Season both sides generously with your favorite burger seasoning. The patties should be thick enough to hold all the fillings together but formed firmly enough that they will not fall apart on the smoker grate.

Step 3: Smoke at 250°F

Fire up your smoker to 250°F. Place the burgers directly on the grate and smoke until the internal temperature reaches 165°F, which takes roughly 45 minutes to 1 hour depending on thickness. The low temperature allows the cheddar cubes to melt slowly into gooey pockets throughout the patty while the jalapeños and onion soften completely.

Step 4: Top with American Cheese

During the last few minutes of cooking, top each burger with a slice of American cheese and close the lid so the trapped heat melts it into a smooth, creamy cap. The American cheese on top provides a different melt texture than the cheddar pockets inside, giving you two distinct cheese experiences in every bite.

Step 5: Toast Buns and Assemble

Toast the brioche buns on the grill or griddle until golden. Spread spicy mayo on both sides, place the smoked, cheese-topped patty on the bottom bun, and serve immediately while the cheese is still molten and the interior is hot.