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–+ servings
Three spicy chicken BLT sandwiches with melted cheddar, crispy bacon, tomato, and lettuce on a black plate

Spicy Chicken BLT Sandwich

This spicy chicken BLT sandwich layers juicy grilled chicken thighs, melty pepper jack, crispy bacon, lettuce, and tomato with a creamy spicy aioli on a buttery toasted brioche bun. The thighs are seasoned with hot sauce and BBQ rub, grilled at 375 to 400°F, and cooked to 185°F for tender, juicy meat.
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Prep Time 20 minutes
Cook Time 20 minutes
Total Time 40 minutes
Servings: 6 sandwiches
Course: Lunch, Main Course
Cuisine: American, BBQ
Ingredients Equipment Method Notes

Ingredients
  

For the Chicken
  • 6 boneless, skinless chicken thighs
  • 2 tbsp hot sauce
  • 2 tbsp BBQ seasoning or chicken rub your favorite
  • 6 slices pepper jack cheese
For the Spicy Aioli
  • 1/2 cup mayonnaise
  • 2 tbsp hot sauce
  • 1 tbsp honey
  • 1 tsp Dijon mustard
  • 1 tsp lime juice
  • 1 clove garlic, grated
  • 1 pinch salt
For the Sandwiches
  • 6 brioche buns
  • butter, for toasting
  • 12 slices bacon cooked crispy
  • lettuce
  • tomato slices seasoned with a pinch of seasoning

Equipment

  • Grill (Gas or Charcoal)
  • Instant-Read Thermometer
  • Small Mixing Bowl
  • Whisk
  • Skillet or Griddle

Method
 

Prep & Sauce
  1. Coat the chicken thighs with hot sauce and season generously with your favorite BBQ rub.
  2. In a small bowl, combine the mayonnaise, hot sauce, honey, Dijon mustard, lime juice, grated garlic, and salt. Mix until smooth and set aside.
Grill & Build
  1. Preheat your grill to 375 to 400°F. Grill the chicken thighs for 5 to 7 minutes per side, until they reach an internal temperature of 185°F. During the last minute, top each thigh with a slice of pepper jack and let it melt.
  2. Brush the brioche buns with butter and toast until golden brown.
  3. Spread spicy aioli on the bottom bun. Add lettuce, seasoned tomato slices, the cheesy grilled chicken thigh, and crispy bacon. Drizzle on more aioli, finish with the top bun, and serve immediately.

Notes

Cook Thighs to 185°F: Chicken is safe at 165°F, but thighs eat better around 185°F, where the connective tissue renders for tender, juicy meat. Use an instant-read thermometer.
Melt the Cheese Last: Add the pepper jack during the last minute of grilling and close the lid so it melts without overcooking the chicken.
The Layering Order: Aioli, lettuce, and tomato go on the bottom, with the hot chicken and bacon on top. This keeps the lettuce and tomato crisp under the warm fillings.
Spicy Aioli Make-Ahead: Whisk the aioli up to 5 days ahead and refrigerate. The honey balances the heat and the lime brightens the mayo.
Adjust the Heat: Swap pepper jack for a milder cheese, or add pickled jalapenos and a hotter sauce for more kick.

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