This BBQ pork chop sandwich delivers smoky depth with a sweet finish that’s hard to resist. I’ve refined this method through years of competition cooking and family gatherings.
Thick-cut chops get a dry rub, then slow-grill to lock in juices. Piled high on a toasted bun with tangy sauce, it’s a meal that satisfies every time.
Ingredients for Bbq Pork Chop Sandwich
Thick-cut pork chops and a smoky-sweet rub make this sandwich unforgettable. Simple ingredients, big flavor.
| Ingredient | Amount | Notes |
|---|---|---|
| Bone-In Pork Chops 🍖 | 4 whole | Thick-cut, about 1 inch |
| Brown Sugar 🧈 | 2 tbsp | Light or dark, packed |
| Smoked Paprika 🌶️ | 1 tbsp | For smoky depth |
| Garlic Powder 🧄 | 1 tsp | Not garlic salt |
| Onion Powder 🧅 | 1 tsp | Ground, fine texture |
| Kosher Salt 🧂 | 1 tsp | Diamond Crystal preferred |
| Black Pepper 🌶️ | ½ tsp | Freshly ground |
| Cayenne Pepper 🔥 | ¼ tsp | Optional for heat |
| BBQ Sauce 🍯 | 1 ½ cups | Tangy, store-bought or homemade |
| Hamburger Buns 🍞 | 4 whole | Soft, split and toasted |
| Butter 🧈 | 2 tbsp | For toasting buns |
| Coleslaw Mix 🥬 | 2 cups | Pre-shredded for convenience |
| Mayonnaise 🥫 | ¼ cup | For coleslaw binding |
| Apple Cider Vinegar 🍏 | 1 tbsp | For tang in slaw |
| Granulated Sugar 🍚 | 1 tsp | Balances vinegar acidity |
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The pork chops are non-negotiable here—bone-in, thick-cut (about 1 inch) stays juicy through slow-grilling. Look for good marbling at your butcher or Costco for bulk packs. The dry rub gets its smokiness from smoked paprika; Penzeys or McCormick are reliable brands. Don’t skip the brown sugar—it caramelizes beautifully during cooking.
No smoked paprika? Regular paprika plus a pinch of liquid smoke works in a pinch. For a spicier kick, double the cayenne or add chipotle powder. The BBQ sauce can be any tangy variety—Sweet Baby Ray’s or Stubb’s are solid choices. If you’re making coleslaw from scratch, swap the pre-shredded mix for shredded cabbage and carrot.
Pork chops keep in the fridge for 3-4 days raw, or freeze for 6 months. The dry rub can be mixed ahead and stored in a jar for 1 month. Toasted buns are best fresh, but the slaw holds up for 2 days covered in the fridge.
Why You’ll Love This Recipe
- One Pan Wonder: I sear the pork chops, toss them with the brown sugar and spices, and let the oven do the rest—hardly any cleanup.
- That Smoky Sweetness: The brown sugar caramelizes with the smoked paprika for a sticky, finger-licking glaze on every bite.
- Feeds a Crowd: I’ve served these at backyard barbecues and weeknight dinners alike, and they disappear fast.
- Budget Hero: Bone-in pork chops are affordable, and a little brown sugar plus spices turns them into something special.
Step-by-Step Instructions for BBQ Pork Chop Sandwich
Master this method for juicy chops and a balanced sandwich with every bite.
Step 1: Season and Grill the Bone-In Pork Chops
Combine the 2 tbsp brown sugar, 1 tbsp smoked paprika, 1 tsp garlic powder, 1 tsp onion powder, 1 tsp kosher salt, 0.5 tsp black pepper, and 0.25 tsp cayenne pepper in a bowl. Rub this mixture all over the bone-in pork chops, pressing it into the meat so it adheres well.
Preheat your grill to medium-high heat. Place the seasoned pork chops on the grill and cook for 5-6 minutes per side. You’re aiming for an internal temperature of 145°F and grill marks that are deep and charred. Avoid flipping too often—let the chops develop a crust before turning.
Step 2: Glaze with BBQ Sauce and Rest
During the last 2 minutes of grilling, brush the pork chops generously with 1.5 cups BBQ sauce. Let the sauce caramelize slightly on the meat, creating a sticky, smoky glaze. This step adds layers of flavor and ensures the chops stay moist.
Once the pork chops reach temperature, transfer them to a cutting board and let them rest for 5 minutes. This allows the juices to redistribute, so every bite remains tender and flavorful. Tent them loosely with foil to keep warm.
Step 3: Toast the Hamburger Buns
Spread the 2 tbsp butter evenly on the cut sides of the 4 hamburger buns. Place them butter-side down on the grill or a skillet over medium heat. Toast for 1-2 minutes until they are golden brown and slightly crisp.
Watch closely to prevent burning. The buns need to be sturdy enough to hold up to the juicy pork chops and toppings without becoming soggy.
Step 4: Prepare the Coleslaw
In a bowl, combine the 2 cups coleslaw mix, 0.25 cup mayonnaise, 1 tbsp apple cider vinegar, and 1 tsp granulated sugar. Stir until the slaw is evenly coated. The mixture should be creamy but not dripping.
Let it sit for 5 minutes to allow the flavors to meld. The vinegar adds a tangy brightness that cuts through the richness of the pork and BBQ sauce.
Step 5: Assemble the Sandwiches
Slice the pork chops if needed to fit the buns. Place a pork chop on the bottom half of each toasted bun. Top with a generous portion of the coleslaw, then drizzle with additional BBQ sauce if desired. Add the top bun and press down gently.
Serve immediately while the pork is still warm and the buns are crisp. Each sandwich should be stacked high with a perfect balance of smoky, sweet, and tangy flavors.
Pro Tips For Making Bbq Pork Chop Sandwich
- Sear First, Sauce Later: Get a hard sear on those bone-in pork chops in a screaming hot pan before adding any BBQ sauce—I learned this the hard way after ending up with steamed meat instead of caramelized edges.
- Dry Brine Overnight: Salt the pork chops generously with the brown sugar, garlic powder, and onion powder mix at least 12 hours ahead; it actually changes the outcome by keeping them juicy through the cook.
- Skip the Pre-Boiled Sauce: Resist the urge to simmer your BBQ sauce separately; brush it on during the last 2-3 minutes of cooking so it sticks to the chops without turning into a sticky, burnt mess.
- Rest Before Slicing: Give the pork chops a solid 5-10 minutes under foil after cooking—yes, even if you’re starving—so the juices redistribute instead of pooling in your sandwich bun.
Essential Equipment for This Dish
Grill Selection
For these sandwiches, I rely on my Weber Genesis gas grill for consistent medium-high heat. The three-burner setup gives me zones for direct and indirect cooking. If you’re a charcoal purist, a 22-inch kettle grill with a chimney starter gets you to the right temperature quickly.
Instant-Read Thermometer
Never guess doneness again. My ThermoWorks Thermapen gives accurate reads in 2-3 seconds. Look for 145°F internal temp in the thickest part of the chop, avoiding the bone. It’s the difference between dry pork and perfect juiciness. 🌡️
Grill Tools
Long-handled stainless steel tongs and a basting brush are essential. I prefer OXO’s 12-inch tongs for their grip and durability. A silicon basting brush handles the sticky BBQ sauce without melting or shedding bristles.
Butter Brush
For toasting buns, a dedicated pastry brush works better than the grill brush. I keep one just for butter applications. The 1-2 minute toast at medium heat needs even butter distribution for that perfect golden crust.
Resting Setup
A wire rack over a sheet pan creates airflow for resting chops. Tent with foil to keep warm during the crucial 5-minute rest. This setup prevents soggy buns while you assemble the sandwiches.
Serving Trays
I use a bamboo serving board for presentation. The natural wood complements the rustic feel of BBQ. Have small bowls ready for extra sauce and coleslaw topping adjustments. 💛
Nutrition Facts
Trained in classic French technique but raised on slow-cooked ribs and spicy rubs, she blends culinary skill with smoke and soul.
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