Grilled Italian Sausage

This restaurant-quality grilled Italian sausage transforms a simple backyard cookout into a gourmet experience. The combination of perfectly charred sausage, tangy olive relish, and herbaceous aioli creates layers of flavor that elevate this dish far beyond an ordinary hot dog.

I first created this recipe when hosting an impromptu summer gathering, and it's become my signature dish that friends specifically request when they visit. The combination of charred sausage with bright, tangy toppings creates a perfect balance that keeps everyone coming back for seconds.

Ingredients

• Fresh Italian sausage links: Hot or mild variety depending on your preference. Look for sausages with visible herbs and a good fat content for the best flavor
• Brioche hot dog rolls: The buttery richness perfectly complements the savory sausage. Seek out fresh bakery rolls if possible
• High quality mayonnaise: For the aioli base. Choose a brand made with real eggs for the best texture and flavor
• Fresh basil leaves: Use bright green leaves without any dark spots for the most vibrant aioli
• Lemon zest: Adds brightness to cut through the richness. Use organic lemons if possible for better flavor
• Garlic cloves: Choose firm bulbs without any sprouting for the cleanest flavor
• Castelvetrano olives: These bright green olives have a buttery texture and mild flavor that works perfectly in the relish
• Giardiniera: Italian pickled vegetables add tang and texture. Available in mild or hot varieties
• Capers: These tiny flavor bombs add a briny punch to the relish. Rinse if you find them too salty
• Balsamic glaze: A sweet finishing touch. Look for a thick, syrupy consistency

Step-by-Step Instructions

Preheat the Grill:

Create two distinct cooking zones on your grill. For gas grills, turn half the burners to high and leave the others off. For charcoal, pile coals on one side of the grill. This dual-zone setup allows for perfect cooking control, starting with gentle heat that cooks the sausage through without burning the exterior, followed by direct heat for that perfect char.

Prepare the Lemon Basil Aioli:

Add mayonnaise, fresh basil, lemon zest, garlic, salt, and pepper to your food processor. Process until completely smooth and vibrant green. The bright herbal notes of the basil and the citrusy punch of lemon zest transform ordinary mayonnaise into a restaurant-quality condiment. This comes together in just minutes but tastes like something that took hours.

Create the Castelvetrano Giardiniera Relish:

Using the same food processor without even cleaning it, combine olives, giardiniera, and capers. Pulse just 3-5 times until roughly chopped but not pureed. You want texture in this relish. The combination creates an Italian-inspired topping with briny, tangy, and slightly spicy notes that perfectly cut through the richness of the sausage.

Start Grilling with Indirect Heat:

Place sausages on the indirect heat side of the grill, near but not directly over the flame. Close the lid and cook for 4-5 minutes. The circulating heat gently cooks the sausages through without causing them to split or dry out. Flip and continue cooking another 4-5 minutes until they reach 150°F internally.

Finish with Direct Heat:

Move sausages directly over the flames and grill 2-3 minutes per side until beautifully charred and internal temperature reaches 160°F. This final step creates that irresistible smoky flavor and satisfying snap when you bite in. The caramelization of the natural sugars in the meat adds depth of flavor.

Toast the Brioche Rolls:

Lightly spray brioche rolls with cooking spray and place them cut-side down directly over the heat. Grill for about a minute until golden brown and slightly crisp. The toasting creates a barrier that prevents the bread from becoming soggy when you add the toppings, while also adding another layer of flavor.

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The Castelvetrano olives are truly the secret weapon in this recipe. I discovered them years ago at an Italian market and have been obsessed ever since. Their buttery texture and mild flavor convert even people who think they don't like olives. My nephew who refuses to eat anything green devoured two of these sausages and asked for the recipe.

Make-Ahead Options

Both the lemon basil aioli and the olive relish can be prepared up to several days in advance. The aioli will stay fresh in an airtight container in the refrigerator for up to one week, though the vibrant green color may darken slightly after a few days. The relish actually improves after a day or two as the flavors meld together and can be stored for up to two weeks. Having these components ready makes assembly incredibly quick when you're ready to grill.

Perfect Pairings

Serve these Italian sausages alongside a simple arugula salad dressed with lemon juice and olive oil to cut through the richness. A crisp Italian white wine like Pinot Grigio or Vermentino provides the perfect refreshing counterpoint to the bold flavors. For a non-alcoholic option, try sparkling water with a splash of blood orange juice and a sprig of rosemary. Complete the meal with grilled peaches drizzled with honey and a dollop of mascarpone for dessert.

Ingredient Substitutions

If you can't find Castelvetrano olives, green Cerignola olives make a good substitute, though they're slightly less buttery in texture. For a dairy-free version, use brioche-style grain rolls made without butter. The aioli can be made with vegan mayonnaise without compromising much on flavor. If fresh basil isn't available, substitute with prepared pesto and omit the garlic for a similar flavor profile. Turkey or chicken Italian sausage can replace pork sausage for a leaner option.

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These sausages are a true crowd-pleaser—a bit of effort that yields incredible results every time!

Frequently Asked Questions

→ What's the best type of Italian sausage to use?

Both hot and mild Italian sausages work well in this dish. If serving guests with varied spice preferences, mild is more universally appealing. For the best flavor, look for fresh sausage links from a butcher rather than pre-packaged varieties.

→ Can I make the toppings ahead of time?

Yes! The lemon basil aioli can be made up to a week in advance and stored in an airtight container in the refrigerator. The castelvetrano giardiniera relish keeps even longer - up to two weeks refrigerated. This makes prep for entertaining much easier.

→ What is zone grilling and why is it important for sausages?

Zone grilling means creating areas of direct high heat and indirect lower heat on your grill. This technique is crucial for sausages as it allows them to cook through gently on indirect heat first (preventing splitting and drying out) before getting a perfect char over direct heat.

→ Can I substitute the brioche rolls with another type of bread?

Absolutely. While brioche adds a buttery richness that complements the sausage, you can substitute with ciabatta rolls for a chewier texture, pretzel buns for a more robust flavor, or traditional hot dog buns for a classic approach.

→ What can I serve alongside these Italian sausages?

These grilled sausages pair wonderfully with Italian-inspired sides like a simple arugula salad with lemon vinaigrette, grilled vegetables such as zucchini or bell peppers, roasted potatoes with rosemary, or a classic pasta salad with fresh herbs.

→ Can I make this dish without a grill?

Yes! You can replicate this dish using a grill pan or cast iron skillet. Cook the sausages over medium heat until they reach 150°F internally, then increase the heat to high for the final sear. You can toast the rolls in a toaster oven or under a broiler.