Smoke-a-fried Bologna Sandwich

Name: Smoke-a-fried Bologna Sandwich
Prep time: 15 min
Cook time: 3 h
Total time: 3 h 15 min
Yield: 4-people
Cuisine: American
Ingredients: 3 lb bologna roll; 1/4 cup seasoning – we used Tuffy Stone’s Everything seasoning; 1/2 cup barbecue sauce – we used Tuffy Stone’s Original BBQ sauce.; 2 Tbsp Yellow Mustard; Pickles; Mayo; Lay’s Original Chips; Brioche Buns; 1 stick of butter

January 5, 2026|Jacob Mauzey

Re-imagine a classic American staple with this smoky, cast-iron finished favorite. It’s the ultimate way to bring huge wood-fired flavor to a simple lunch using your pellet grill and a few easy steps.

Smoke-a-fried Bologna Sandwich

Rated 5.0 stars by 1 users

Cuisine

American

Author:

Jacob Mauzey

Servings

4-people

Prep Time

15 minutes

Cook Time

3 hours

If you haven’t ever had a fried bologna sandwich you’ve only been cheating yourself. We took this already excellent sandwich and turned it up a notch by smoking the bologna roll first. Don’t take our word for it, try it for yourself and enjoy with friends and family.

Cook Mode

Sandwich with a thick slice of bologna, mustard, and pickles on a toasted brioche bun

Ingredients

3 lb bologna roll
1/4 cup seasoning – we used Tuffy Stone’s Everything seasoning
1/2 cup barbecue sauce – we used Tuffy Stone’s Original BBQ sauce.
2 Tbsp Yellow Mustard
Pickles
Mayo
Lay’s Original Chips
Brioche Buns
1 stick of butter

Directions

Preheat your Prime300 pellet grill to 250 degrees.
Take the bologna roll and score lines that are about 1/2″ to 1″ deep spaced evenly across the surface of the roll. I cut end to end and then circumference with roughly 1.5″ spacing.
Spread some mustard on the roll, you won’t need very much, just enough to somewhat coat in a thin layer, about 2 tbsp.
Evenly spread seasoning across the whole roll and place on your now heated grill. Since bologna is already fully cooked through, we are just looking for the smoke flavor. I usually leave the roll on for about 3 hours in total.
After the first hour, take the roll off and glaze with about half of the barbecue sauce and place back on the smoker. Repeat this with the remaining sauce and smoke for another hour.
At the end of the 3 hours you should see the sauce caking somewhat to the bologna and creating a bit of a crust, if this hasn’t happened yet you can add another 30 minutes or so of smoke. Remove from the grill and wrap to rest for at least 30 minutes up to 2 hours. Longer is better but not necessary if time restricts. Shut off grill.
Place a cast iron pan above the sear plate. Open the slide and increase the grill to 450 degrees. NOTE: ***If your grill is not clean or has a significant amount of grease/fat on the sear plate/grates you will need to clean it off before this step. Failure to do so could result in a grease fire.***
While the grill is heating up, unwrap your bologna roll and slice it evenly to your preference. I prefer somewhere between 1/4″ and 1/2″ slices.
Once the grill and cast iron are very hot, add 2 Tbsp of butter to the pan and start adding slices of bologna to the melted butter. Fry to desired texture. For me this is about 2-4 minutes per side depending on how hot my cast iron is. Add additional butter as needed until all or desired amount is fried.
Build the sandwiches immediately by placing the regular potato chips and American cheese on the bologna if desired as soon as you pull it from the pan. Add mayo/mustard and pickles grab an ice cold beverage of your choice and enjoy tasting freedom in the form of food!