This is more than just a simple chicken sandwich. It’s a full meal on a bun, featuring juicy grilled chicken, crispy bacon, melted pepper jack, and a homemade charred onion mayonnaise that ties it all together.
With all the components, it takes about 50 minutes to prepare and cook. The process is straightforward, and you can make the special sauce ahead of time to get a head start on dinner.
Why You’ll Love Grilled Chicken Sandwich
- Pounding the chicken to an even thickness helps it cook quickly and evenly, keeping the meat juicy.
- Grilling the onion before adding it to the mayonnaise creates a deep, smoky flavor that elevates the sauce.
- Toasting the buttered buns is a key step that adds texture and prevents the bread from becoming soggy.
Grilled Chicken Sandwich Ingredients
- Chicken: Boneless, skinless chicken thighs are a great alternative. They are forgiving on the grill and stay very moist.
- Buns: We like brioche for its soft, rich texture, but a sturdy ciabatta roll or kaiser roll will also hold up well to the fillings.
- Cheese: If you prefer less heat, swap the pepper jack for provolone, cheddar, or Swiss cheese.
- BBQ Marinade: Use any store-bought brand you enjoy. You can also make a quick marinade with ketchup, brown sugar, cider vinegar, and spices.
- Bacon: Thick-cut bacon provides the best texture in the sandwich, but any kind of bacon you have on hand will work.
- Mustard: Dijon mustard can be used in place of spicy brown mustard for a slightly different tang.
Exact quantities are in the recipe card below.
How to Make Grilled Chicken Sandwich
Step 1: Marinate the Chicken
First, pound the chicken breasts to an even thickness so they cook uniformly. Place them in a bag with your favorite BBQ marinade and let them rest in the refrigerator while you prepare the other ingredients.
Step 2: Make the Charred Onion Mayo
While the grill preheats, cook the thick red onion rings until they are tender and have nice grill marks. Finely chop the cooked onion and mix it with mayonnaise, mustard, and lemon juice to create a smoky, flavorful sauce.
Step 3: Grill the Bacon and Chicken
Cook the bacon on the grill until it’s crispy, then set it aside. Grill the marinated chicken until it’s fully cooked. In the final minute, top the chicken with cheese and toast the buttered buns on the grill.
Step 4: Assemble the Sandwiches
Now it’s time to build your sandwich. Spread the charred onion mayo on the toasted buns. Layer the lettuce, tomato, cheesy chicken, crispy bacon, and sliced avocado. Add the top bun and serve right away.
Storage Tips for Grilled Chicken Sandwich
Store leftover components separately in airtight containers in the refrigerator for up to 2 days. Reheat the chicken in a skillet or microwave until warmed through. It is best to assemble the sandwiches just before serving. Freezing is not recommended.
Expert Tips for Grilled Chicken Sandwich
- Food Safety: Ensure chicken is cooked to a safe internal temperature of 165°F (74°C). Use an instant-read thermometer for an accurate reading.
- No grill? Use a cast-iron grill pan on your stovetop over medium-high heat. You may need to cook in batches and ensure your kitchen is well-ventilated.
- The charred onion mayo can be made up to 2 days in advance and stored in an airtight container in the refrigerator.
- For even melting, you can close the grill lid for the last minute after adding the cheese to the chicken.
What to Serve with Grilled Chicken Sandwich?
These sandwiches are quite filling on their own. For a classic meal, pair them with simple potato chips or a creamy coleslaw.
Grilled Chicken Sandwich Recipe FAQs
Can I make this without an outdoor grill?
Yes. A cast-iron grill pan on the stovetop over medium-high heat works well. Cook in batches if needed and make sure your kitchen is well-ventilated, as it can create some smoke.
How can I tell when the chicken is cooked properly?
The most reliable method is to use an instant-read thermometer. Chicken is safe to eat when the internal temperature reaches 165°F (74°C) at the thickest part.
Can I prepare any of this recipe in advance?
Yes, to save time you can make the charred onion mayo up to two days ahead and store it in the refrigerator. The chicken can also be marinated for up to four hours before grilling.
Grilled Chicken Sandwich
Ingredients
- 2 large boneless skinless chicken breasts, about 1.5 lbs / 680g total
- 1 cup your favorite BBQ marinade 240 ml
- 1 large red onion cut into 1/2-inch thick rings, 1.25 cm
- 1/2 cup mayonnaise 115g
- 2 tbsp spicy brown mustard 30g
- 1 tbsp fresh lemon juice 15 ml
- 1 tsp all-purpose BBQ rub or seasoning
- 8 slices thick-cut bacon
- 4 brioche buns sliced
- 4 tbsp unsalted butter softened, 57g
- 4 slices pepper jack cheese
- 4 large lettuce leaves such as green leaf or Bibb
- 1 large ripe tomato cut into 4 thick slices
- 1 medium avocado peeled, pitted, and sliced
Instructions
- Place a chicken breast inside a zip-top bag and use a meat mallet or rolling pin to pound it to an even 1/2-inch (1.25 cm) thickness. Repeat with the other breast. Return both to the bag, add the BBQ marinade, and refrigerate for at least 30 minutes or up to 4 hours.
- Preheat your grill to medium-high heat (about 450°F / 232°C). Lightly oil the onion rings and place them on the grill. Cook for 3-4 minutes per side, until tender and lightly charred. Remove from the grill.
- To make the sauce, finely chop the grilled onion. In a small bowl, combine the chopped onion, mayonnaise, mustard, lemon juice, and BBQ rub. Set aside or refrigerate until ready to use.
- Place the bacon strips on the grill (or on a grill-safe pan). Cook for 5-8 minutes, flipping once, until crispy. Remove and set on a paper towel-lined plate. Spread softened butter on the cut sides of the buns.
- Remove chicken from the marinade, letting any excess drip off. Grill the chicken for 5-7 minutes per side. The chicken is done when an instant-read thermometer inserted into the thickest part registers 165°F (74°C).
- During the last minute of cooking, place a slice of pepper jack cheese on each chicken breast to melt. At the same time, place the buttered buns cut-side down on the grill for about 1 minute to toast.
- Slice each chicken breast in half crosswise. To assemble, spread the charred onion mayo on the top and bottom buns. On the bottom bun, layer lettuce, a tomato slice, a piece of chicken, two slices of bacon, and a few slices of avocado. Place the top bun on and serve immediately.
