How to Make a Grilled, Smoked, Sausage Stuffed Bacon Wrap

by Don Cook

I love to grill, as you already know if you have seen my guides before. Please let me know if you like this recipe or try it yourself. Follow me too, I have a lot more guides coming!


  • 1 ½ Pounds Thick cut bacon
  • 2 Pounds Breakfast and/or sage sausage
  • ½ Pounds Cheese (Asiago, Colby jack, etc)
  • ¼ Pounds Sliced meat (pepperoni, prosciutto, etc)
  • 4 Ounces Fresh spinach
  • BBQ sauce (your favorite, must be sweet)
  • 1 Tablespoon Granulated garlic
  • 1 Tablespoon Onion powder
  • ½ Tablespoons Paprika
  • ½ Tablespoons Black pepper
  • ½ Tablespoons Ground cumin
  • ½ Tablespoons Chili powder
  • 2 Tablespoons Light brown sugar (heaping)
  • ½ Sweet white onion, lightly sautéed
  • Parchment or wax paper
  • Scissors
  • 2 Zip lock bags, gallon sized
  • Instructions

    Step 1

    Add all seasonings to a cup and mix to make the rub. Note that there is no added salt to this recipe due to the amount in the bacon and sausage already. (This picture shows double the amount)

    Step 2

    Cook half a pound of bacon. This is one pound here because I'm making 2 at a time. I prefer to make bacon in the oven so I use a grill rack and spread the bacon out on it. Preheat oven to 425 f.

    Step 3

    Place rack into a larger baking pan lined with aluminum foil. This will help keep the bacon grease away from the bacon (this is why I prefer this method).

    Step 4

    Cook until desired crispness is achieved. This took about 25 minutes, start watching it around 15 minutes in. For this recipe I prefer the bacon to be very crispy.

    Step 5

    Once it cools, pat the bacon dry with a paper towel then cut up the bacon into smaller pieces.

    Step 6

    Chop up half a sweet, white onion into small pieces.

    Step 7

    Sauté Onion with just a touch of vegetable oil until they just start to turn brown. You want the onion soft but not soggy.

    Step 8

    Create your bacon weave. Start with the horizontal rows and weave the vertical pieces in. Make sure you use thick cut bacon. Anything thinner won't work out as well.

    Step 9

    Pull back the horizontal pieces that will go over the next vertical piece. This makes weaving them much easier.

    Step 10

    This is what a 1-pound completed weave looks like.

    Step 11

    Sprinkle rub over the bacon weave.

    Step 12

    Place two pounds of sausage into a gallon ziplock bag. For this recipe I have one pound each of breakfast and sage sausage. You can use whatever your preference is.

    Step 13

    Mix and flatten out the sausage all within the bag. It will be easier to flatten the more air is out of the bag. Then unzip and cut the sides to be able to remove the sausage patty.

    Step 14

    Lay the sausage patty over the bacon weave. Add cheese. This is a layer of crumbled asiago and then some shredded Colby jack. Sprinkle more of the rub over the cheese.

    Step 15

    Add some of your favorite BBQ sauce. You are generally going to want a sweeter BBQ sauce. I use Sweet Baby Ray's.

    Step 16

    You can add some other meat now if you want. This is prosciutto, but you can use pepperoni or even thin slices of salami. .

    Step 17

    Remember your sautéed onion and bacon pieces? Add them now. Spread them out all over.

    Step 18

    You can add greens now if you like. I'm using fresh spinach.

    Step 19

    Now, roll up the sausage very tightly. Leave the bacon weave behind. Squeeze the ends of the sausage roll together so they are fully closed up. Careful not to tear the sausage patty.

    Step 20

    Roll the sausage back toward you, wrapping the weave around it tightly. At this point you can roll it into the parchment paper to store it overnight if you aren't going to smoke it right away.

    Step 21

    You can place it right onto your grill rack but I prefer to use a mesh tray Ike this one. Put some rub all over before you begin smoking.

    Step 22

    As always place it away from direct heat. Around 225 F is best but a little bit higher wont hurt. The best wood to smoke this with will be apple wood and mesquite. I'm using both.

    Step 23

    Make sure you are measuring the internal temperature closely. You will cook this to 165 F.

    Step 24

    Having an internal thermometer with a remote is really handy. This one lets me set an alarm on it as well.

    Step 25

    This is about 1.5 hours into the cook. I had to add more wood, but you won't want to open your grill or smoker often. The more you do, the longer it will take.

    Step 26

    At approximately 3 hours total the thermometer alarm went off and it was done. I double wrapped it into foil to bring to dinner.

    Step 27

    This is sliced in half. I didn't notice the flash didn't go off so its a little dark in this picture.

    Step 28

    Top view. Slice it into 1/2 inch pieces. Or more. Whatever you feel like.

    Step 29

    On the plate. Nice smoke ring and delicious all the way through! Enjoy!