Forget everything you thought you knew about the classic Italian sub. This isn't your grandma's lunchtime staple; we're taking the beloved flavors of Italy and grilling them to perfection, creating a smoky, juicy, and intensely flavorful experience. Imagine tender Italian sausage bursting with herbs, crisp bell peppers sizzling on the grill, and melted provolone cheese oozing between perfectly toasted bread. This isn't just a sandwich; it's a culinary adventure.
We're going to elevate the humble chopped Italian to BBQ heights with a recipe that's both simple and surprisingly sophisticated. Get ready to ditch the pre-made and embrace the incredible taste of a homemade masterpiece. This step-by-step guide will walk you through each stage, ensuring your grilled chopped Italian sandwich is a resounding success.
Tools Needed
- YS-640S Pellet Grill
- Knife
- Cutting Board
Ingredients
- Salami
- Pepperoni
- Ham
- Mayonnaise
- Vinegar (balsamic preferred)
- Tomato
- Romaine Lettuce
- Provolone Cheese (or similar)
- Italian Seasoning (Cattleman's Grill Italiano)
- French Loaf Bread: 1
- Pepperoncini
Step-by-Step Instructions
Step 1. Grill and Prep the Meats
- Grill salami, pepperoni, and ham on the pellet grill until slightly crisp.

Step 2. Combine Filling Ingredients
- Chop the grilled meats, tomatoes, and lettuce roughly.
- Combine the chopped meats, cheese, and vegetables in a bowl.
- Add mayonnaise, balsamic vinegar, and Italian seasoning to the mixture. Mix well.



Step 3. Assemble the Sandwich
- Hollow out a French loaf, leaving enough room for the filling.
- Stuff the loaf with the chopped Italian mixture.
- Garnish with pepperoncini.



Step 4. Serve
- Slice the sandwich into portions and serve.

Read more: Classic Beef Spiedini: Italian-Style Kebabs Recipe
Tips
- Don't overcook the meats; you just want a little crispness.
- Use equal parts of each meat and cheese by weight for balanced flavor.
- Rough chopping is fine, as everything will be mixed together.
- Use a good quality Italian dressing or seasoning for enhanced flavor.
Nutrition
- N/A
FAQs
1. Can I use different types of sausage?
Absolutely! Try spicy Italian sausage, chicken sausage, or even a vegetarian alternative for variety.
2. What kind of cheese melts best?
Provolone is classic, but mozzarella, provolone-mozzarella blend, or even pepper jack work well too. Choose a cheese that melts easily.
3. How do I prevent the bread from burning on the grill?
Use medium heat and keep a close eye on it. You can also lightly brush the bread with olive oil to prevent sticking and help with browning.
So there you have it – a grilled chopped Italian sandwich that's anything but ordinary. This recipe elevates a classic to new heights of flavor and texture, perfect for a casual weeknight meal or a crowd-pleasing party snack. Now get grilling and prepare to be amazed!