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Published June 20, 2016. This post may contain affiliate links. Please read my disclosure policy.
Warm weather is finally here which means we are outside all day long and are entertaining like crazy. In our Chicago home room is always tight and going outside helps us expand to having more people over while being comfortable. When I made this Smoked Chicken Sandwich with Chipotle Mayonnaise we practically called the neighborhood over because they were already harassing all day from the wonderful smoke smells coming from my Big Green Egg®! There are certain smells like caramelized onions and grilled/smoked foods that immediately make me salivate and crave them. I feel like when I got to do this recipe I introduced a little bit of that smoky south goodness up north here in Chicago and people LOVED it!
When smoking any meats, you have to account for the time it takes to do so because it’s really a two-step process. The first is developing a really tasty rub to go on your protein and along with that comes time in the refrigerator to let all of those wonderful flavors infuse in. The longer the better of course, but it has to at least be 2 hours and as much as 48 hours. The second part is the time it takes to smoke your food. While this sandwich used chicken breasts, these same methods apply to anything you smoke. In fact some people take it a step further and brine their protein first, before adding the rub and then smoking, yup those are the diehard Q’ers!
Smoking meats for your sandwich definitely takes some practice, especially when using an open flame. Not going to lie, it took me a few times to get it right the first time I ever did it so don’t feel discouraged if you don’t hit a home run on the first try. Just remember that when you light your combination of coals and desired woods for smoking that you need to close the lid once the fire catches to make sure you maintain sub 275° temperatures. If you don’t know, smoked BBQ is all about slow and low so that last step is crucial because the Big Green Egg® gets super-hot super-fast and before you know it you’ll be at 700°. After that it’s a walk in the park, which is perfect because during that smoking time (about 2 hours) we can prep up our epic Smoked Chicken Sandwich with Chipotle Mayonnaise!
This sandwich has a lot going on, but my promise to you is that once you sink your teeth in you will be blown away at the flavor combinations. My wife literally told me it was the best sandwich she’s ever had, and with any great sandwich like this one it starts with the bun. For me all sandwich buns should be toasted because some of those sweet flavors that are natural in breads comes to the front once browned.
The vegetable toppings on this sandwich include heirloom tomatoes, fresh avocado, kale microgreens and butter leaf lettuce. If you aren’t able to get microgreens at your local store than simply use alfalfa sprouts, no problem!
Notice I said vegetable toppings because I’m not done yet!! I loaded this sandwich up with crispy bacon, lean ham, a fried egg, mozzarella, pepper jack cheese and a chipotle mayonnaise that will soak into your toasted Cobblestone Bread Co.™ Sesame Twist Bun and will be oh so delicious!! The little foil packets in the image are actually the smoked chicken breasts, which stay nice and moist wrapped in foil after removing them from the smoker once they hit 165°.
As I said earlier it’s crucial to toast the bun because we are loading on juicy ham, sliced smoked chicken and melty cheese all over it and you need a bread like this toasted Cobblestone Bread Co.™ Sesame Twist Bun which can stand up to all the juices without falling apart.
Once the cheese has melted over top of the chicken and ham it’s time to layer up. I added the tomatoes, lettuce, bacon, fried egg, avocado then microgreens, followed up by the chipotle mayo smothered toasted Sesame Twist Bun.
Smoked Chicken Sandwich with Chipotle Mayonnaise
For the Chicken:
- 3 tablespoons of brown sugar
- 1 ½ teaspoons of dry oregano
- 1 ½ teaspoons of onion powder
- 1 ½ teaspoons of garlic powder
- 1 ½ teaspoons of Kosher salt
- 1 teaspoon of ground mustard
- ¼ teaspoon of ground ginger
- ¼ teaspoon of chili powder
- ¼ teaspoon of chipotle powder
- ¼ teaspoon of paprika
- 6 chicken breasts
For the Mayonnaise:
- 2 cups of mayonnaise
- 3 finely minced chipotle peppers in adobo sauce
- 1 ½ tablespoons of red wine vinegar
- 1 teaspoon of sugar
- Kosher salt to taste
For the Toppings:
- 3 thinly sliced heirloom tomatoes
- 1 head of butter leaf lettuce, leaves reserved only
- 2 thinly sliced avocados
- 2 cups of packed kale microgreens
- 24 pieces of crisp cooked bacon
- 1 pound on thinly sliced lean ham
- 12 fried eggs to desired amount of doneness
- 12 slices of mozzarella cheese
- 12 slices of pepper jack cheese
- 12 to asted Cobblestone Bread Co.™ Sesame Twist Buns
- Chicken: Combine all of the herbs and spices in a small bowl and generously add and rub into the chicken breasts on all sides and let it marinate for at least 2 hours and up to 48 hours.
- Smoke the chicken on a Big Green Egg® for 2 hours or until the chicken reaches an internal temperature of 165°. Once it is to temperature wrap each breast in foil and let stand for 30 minutes before slicing.
- Mayonnaise: Whisk together all of the ingredients in a medium size bowl until combined and keep cool before serving.
- To Plate: Spread a small amount of the chipotle mayonnaise onto the top of a toasted sesame bun and set aside.
- Next, add a few slices of ham and smoked chicken to the bottom part of a toasted bun along with a slice of each mozzarella and pepper jack and melt under a broiler. Layer on the sliced tomatoes, butter leaf lettuce crispy bacon, sliced avocado, fried egg, micro greens and the top of the bun with chipotle mayonnaise. Repeat the process 11 more times evenly using up all of the ingredients.