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This smoked and fried bologna sandwich starts with a whole beef bologna chub smoked over applewood, then griddle-fried into crispy slices. You score and smoke the chub, glaze it with BBQ sauce, then slice and fry each piece. Melted American cheese, spicy mayo, and brioche pull it together. Smoking at 250°F builds bark before the fry adds a crispy edge. This recipe makes 8 sandwiches for a crowd. Load them with lettuce, pickles, and an optional tomato.

What Makes This Bologna Sandwich

Smoked and Fried

This smoked bologna sandwich uses two cooking methods for big flavor. First, you smoke a whole bologna chub low and slow. The smoke builds a bark and deep flavor. Then you slice and fry each piece on a griddle. Frying adds a crispy, caramelized edge. As a result, every bite has smoke and crunch.

The Spicy Mayo

A spicy mayo ties this smoked bologna sandwich together. Combine mayonnaise, Dijon mustard, and hot sauce in a bowl. Then add Cajun seasoning, garlic powder, and lemon juice. Mix it well and chill it until you build the sandwich. The creamy heat balances the rich bologna. As a result, the sauce cuts through the smoke and fat.

Prepping and Scoring the Bologna

Scoring the Chub

Scoring is the first step for a great smoked bologna sandwich. Cut a crosshatch pattern about 1/4 inch deep around the chub. Make vertical cuts, then horizontal cuts, to form squares. The scoring lets smoke and rub reach the inside. It also builds more bark surface. As a result, the bologna soaks up more flavor.

Binder and Rub

A binder helps the rub stick to the bologna. Coat the chub with Dijon mustard or hot sauce. Then season generously with your favorite sweet BBQ seasoning. The binder holds the rub in place. The sweet rub balances the salty bologna. As a result, the surface builds a sweet, savory crust.

Smoking the Bologna

Applewood at 250°F

Smoke gives this smoked bologna sandwich its signature flavor. Preheat your smoker to 250°F using applewood. Then place the whole chub on the grate. Applewood adds a mild, sweet smoke that suits bologna. Tent it loosely with foil if it darkens too fast. As a result, the bologna smokes evenly without burning.

Glazing to 145°F

Cook the bologna until it hits the target temperature. Smoke it until the internal temperature reaches 145°F. About 10 minutes before it is done, brush on your favorite BBQ sauce. Let the glaze caramelize on the bark. Then remove the chub and rest it for 10 minutes. As a result, the glaze sets into a sticky, sweet layer.

Slicing and Frying

Preventing the Curl

Slicing sets up the fry for this smoked bologna sandwich. Slice the rested bologna as thin or thick as you like. Then cut a small slit from the center of each slice to the edge. The slit stops the slice from curling in the pan. Flat slices fry and brown evenly. As a result, each piece lays flat on the griddle.

Frying and Melting Cheese

Frying adds the crispy finish to a smoked bologna sandwich. Heat a skillet or griddle over medium-high heat. Fry each bologna slice for about 1 minute per side. Then top each slice with 2 slices of American cheese. Let the cheese melt over the hot bologna. As a result, you get a crispy, cheesy layer.

Building the Sandwich

Toasting the Buns

Toasted buns give this smoked bologna sandwich a sturdy base. Butter the brioche buns on the cut sides. Then toast them until golden brown. Toasting adds crunch and keeps the bun from going soggy. Brioche brings a soft, slightly sweet bite. As a result, the bun holds up to the juicy bologna.

Layering It Up

Layering builds the finished sandwich. Spread spicy mayo on the bottom bun. Then add shredded lettuce, the cheesy fried bologna, and dill pickle chips. Add an optional slice of tomato for freshness. Spread more spicy mayo on the top bun and close it. As a result, every layer adds flavor and texture.

Step-by-Step: How to Make a Smoked and Fried Bologna Sandwich

Step 1: Make the Spicy Mayo

In a small bowl, combine the mayonnaise, Dijon mustard, hot sauce, Cajun seasoning, garlic powder, and lemon juice. Mix well and refrigerate until ready to use.

Step 2: Score, Bind, and Season the Bologna

Score the bologna about 1/4 inch deep with vertical then horizontal cuts to make a crosshatch pattern around the whole chub. Coat it with Dijon mustard or hot sauce as a binder, then season generously with your favorite sweet BBQ seasoning.

Step 3: Smoke and Glaze

Preheat your smoker to 250°F using applewood. Smoke the bologna until it reaches an internal temperature of 145°F, tenting loosely with foil if it darkens too fast. About 10 minutes before it is done, brush with BBQ sauce and let it caramelize.

Step 4: Rest, Slice, and Slit

Remove the bologna and let it rest for 10 minutes. Slice it as thin or thick as you prefer, then cut a small slit from the center of each slice to the outer edge to help prevent the bologna from curling while frying.

Step 5: Toast Buns and Fry the Bologna

Butter the brioche buns and toast until golden brown. Heat a skillet or griddle over medium-high heat and fry the bologna slices for about 1 minute per side, then top each slice with 2 slices of American cheese and let it melt.

Step 6: Assemble and Serve

Spread spicy mayo on the bottom bun, then layer with shredded lettuce, the cheesy fried bologna, dill pickle chips, and optional sliced tomato. Spread more spicy mayo on the top bun, place it on the sandwich, and serve immediately.