Name: Grilled Italian Sausage and Pepper Sandwich Recipe
Prep time: 10 min
Cook time: 20 min
Total time: 30 min
Cuisine: Italian-American
Ingredients: 4 mild or spicy Italian sausages; 1 red bell pepper thinly sliced; 1 yellow bell pepper thinly sliced; 1 yellow onion thinly sliced; 1 tablespoon olive oil; Salt & ground black pepper to season; ½ cup marinara sauce or your favorite store bought sauce; ½ cup shredded mozzarella cheese; Fresh basil for garnish if desired; 4 buns or rolls of choice

Nothing beats the smoky, savory flavors of a classic Grilled Italian Sausage and Pepper Sandwich Recipe. Imagine juicy sausages nestled in soft buns, topped with sweet charred peppers, onions, tangy marinara sauce, and melted mozzarella – pure comfort on a plate!

Four hot dogs inside white buns are placed on a white marbled surface. Each hot dog has a grilled sausage with browned skin, topped with a mix of grilled red, yellow, and orange thinly sliced bell peppers and onions that have slightly blackened edges. A white sauce is drizzled over all the hot dogs in thick zigzag lines. A small piece of lemon is visible near the top right corner. The image shows close-up detail of the hot dogs’ textures and vibrant colors. Photo taken with an iphone --ar 2:3 --v 7

Jump to:

Why You'll Love This Recipe
Ingredients & Why They Work
Make It Your Way
Step-by-Step: How I Make Grilled Italian Sausage and Pepper Sandwich Recipe
Top Tip
How to Serve Grilled Italian Sausage and Pepper Sandwich Recipe
Make Ahead and Storage
Frequently Asked Questions:
Final Thoughts
Grilled Italian Sausage and Pepper Sandwich Recipe

Why You'll Love This Recipe

I’ve made this grilled Italian sausage and pepper sandwich more times than I can count, and every time, it feels like the perfect easy dinner or weekend cookout favorite. It’s a total crowd-pleaser and comes together quickly with simple ingredients.

Simple ingredients: Uses basic, easy-to-find items that pack big flavor.
Quick grilling: Ready in just 30 minutes, perfect for busy weeknights or a relaxed weekend meal.
Customizable heat: Choose mild or spicy sausages depending on your spice level.
Perfectly balanced: Sweet peppers and onions complement the savory sausage, all topped with melty mozzarella.

Ingredients & Why They Work

The magic of this grilled Italian sausage and pepper sandwich starts with fresh, quality ingredients. When shopping, pick sausages that suit your heat preference and look for colorful, firm bell peppers. A good marinara sauce and fresh mozzarella finish things off beautifully.

Flat lay of four fresh Italian sausages with natural casing, thinly sliced red bell pepper strips, thinly sliced yellow bell pepper strips, thinly sliced yellow onion rings, a small white bowl of golden olive oil, a small white bowl of vibrant red marinara sauce, a small white bowl filled with shredded mozzarella cheese, a few whole fresh basil leaves, and two plain soft buns, all arranged symmetrically in a balanced composition on simple white ceramic plates and bowls, placed on a clean white marble surface, soft natural light, photo taken with an iPhone, professional food photography style, fresh ingredients, white ceramic bowls, no bottles, no duplicates, no utensils, no packaging --ar 2:3 --v 7 --p m7354615311229779997

Italian sausages: Mild or spicy, they’re the star protein with tons of flavor and juicy texture when grilled.
Red bell pepper: Adds sweetness and a vibrant pop of color.
Yellow bell pepper: Brings a mild, fruity note to the mix.
Yellow onion: Offers a savory balance and caramelizes nicely on the grill.
Olive oil: Helps the vegetables char perfectly without sticking or drying out.
Salt & ground black pepper: Essential seasonings to enhance all the flavors.
Marinara sauce: Adds tangy tomato richness that ties everything together.
Shredded mozzarella cheese: Melts into gooey, cheesy goodness that seals the deal.
Buns or rolls: Soft, sturdy bread that holds up to all the juicy fillings.
Fresh basil (optional): Adds a fragrant herbal finish if you want a little extra pizzazz.

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Note: You'll find the complete list of ingredients, along with their exact measurements, in the printable recipe card at the bottom of this post.

Make It Your Way

One of the best things about this Grilled Italian Sausage and Pepper Sandwich Recipe is how easy it is to customize! Whether you prefer things spicy, mild, or even meat-free, you can tweak it to match your taste and occasion perfectly.

Spicy Upgrade: If you love a kick, I like swapping in spicy Italian sausages. The heat pairs beautifully with the sweet peppers and melty mozzarella, giving every bite a delightful zing.
Vegetarian Option: For a meatless twist, try grilling portobello mushroom caps or your favorite vegan sausages instead – still packed with flavor and just as satisfying!
Cheese Swap: Mozzarella is classic here, but provolone or fontina melt just as well and add a different depth of flavor.
Seasonal Touch: In summer, add a handful of fresh cherry tomatoes to the grill basket for a juicy burst amid the peppers and onions.

Step-by-Step: How I Make Grilled Italian Sausage and Pepper Sandwich Recipe

A sandwich sits in a white paper-lined wire basket on a white marbled table. The sandwich is made of a soft light brown bun holding a grilled sausage that is dark brown with a slightly crispy texture. On top are grilled sliced red and yellow peppers, charred onions, and some small green basil leaves. A white creamy sauce is drizzled over the vegetables. On the side, there are thick grilled potato wedges with a browned and slightly spicy-looking seasoning. A woman's hand is reaching for the basket, and a grey cloth napkin is partially under it. photo taken with an iphone --ar 2:3 --v 7

Step 1: Fire Up the Grill to Medium Heat

Start by preheating your grill to medium heat – this steady temperature ensures the sausages cook evenly without burning, while giving the peppers and onions time to soften and char beautifully. If you want to nail that perfect grill mark on your sausages, give the grill a couple of minutes to heat thoroughly before placing anything on it.

Step 2: Toss and Season Your Veggies

While waiting for the grill, thinly slice the red and yellow bell peppers along with the yellow onion. In a medium bowl, drizzle 1 tablespoon of olive oil over the veggies, then sprinkle with ½ teaspoon each of salt and fresh ground black pepper. Toss everything gently to coat all the slices evenly—this seasoning step is key to drawing out their natural sweetness and caramelizing nicely on the grill.

Step 3: Grill the Sausages to Juicy Perfection

Place all four Italian sausages directly onto the grill grates. Let them sizzle for 5 to 7 minutes on one side before flipping—this gives you those lovely grill lines and locks in the juices. Cook for another 5 to 7 minutes on the other side until they're fully cooked through. You’ll know they’re done when the sausages have firmed up and reach an internal temperature of 160°F. Once cooked, move them to a plate and tent with foil to keep warm, or nestle them on a cooler part of the grill over indirect heat while you tend to the veggies.

Step 4: Char the Peppers and Onions Just Right

While the sausages are grilling, place your seasoned peppers and onions into a grill basket. This trick prevents those smaller slices from slipping through the grates. Grill for 7 to 10 minutes over medium heat, tossing frequently so everything cooks evenly and develops a beautiful char. Listen for that satisfying sizzle and watch as the veggies soften to tender perfection — they should be slightly caramelized with some blackened edges for extra flavor.

Step 5: Build Your Sandwiches and Melt the Cheese

Time to assemble! Place one juicy sausage in each bun or roll. Load up with a generous helping of the grilled peppers and onions, then add 2 tablespoons of marinara sauce over top. Sprinkle ½ cup of shredded mozzarella cheese evenly over the sauce. To melt the cheese perfectly, you can place the assembled sandwiches back on the grill using indirect medium-high heat for 1 to 2 minutes. If you’re indoors or short on time, a quick broil in the oven for 1 to 2 minutes does the trick just as well—keep an eye so the cheese melts without burning.

Step 6: Finish with Fresh Basil and Serve Warm

Add a few fresh basil leaves on top if you like that herbal brightness—it’s a beautiful contrast to the smoky sausage and sweet peppers. Serve these sandwiches warm and dig in! Each bite bursts with classic Italian-American flavors, perfect for a casual dinner or your next cookout.

Top Tip

Getting that perfect balance of smoky sausage and sweet, charred peppers requires a few simple tricks. These tips are the result of many grilling sessions, ensuring your Grilled Italian Sausage and Pepper Sandwich Recipe always comes out delicious and crowd-pleasing.

Use a Grill Basket for Veggies: I’ve found that tossing peppers and onions directly on the grill can get messy and you risk losing some pieces through the grates. A grill basket keeps everything contained and helps you toss evenly for that perfect char.
Keep Sausages Warm on Indirect Heat: After grilling, moving the sausages to a cooler spot on the grill prevents overcooking while you get the veggies ready. This step keeps them juicy and tender.
Melt Cheese on Indirect Heat: Instead of directly on flames, placing the assembled sandwich on the grill with indirect heat melts the mozzarella perfectly without burning the buns.
Don’t Skip Marinating the Veggies: Tossing peppers and onions with olive oil and seasoning ahead of time really amps up their flavor and softens them just right on the grill.

How to Serve Grilled Italian Sausage and Pepper Sandwich Recipe

The image shows a metal tray with three rows of food items neatly arranged. The top row has several slices of purple onion, showing layers from large halves to smaller wedges, all with a shiny, smooth texture and vibrant purple and white color. The middle row has five bell peppers, some whole and some hollowed out, in red, yellow, and orange colors with a glossy, smooth surface. The bottom row has five white hot dog buns, four closed and one open showing a soft, fluffy inside with a golden crust. All items are placed evenly on the tray with clear, bright lighting that highlights their fresh textures and colors. The background is a white marbled surface. photo taken with an iphone --ar 2:3 --v 7

Garnishes

Fresh basil leaves are a beautiful, fragrant garnish that adds a hint of herbal brightness to contrast the richness of the sausage and melted mozzarella. If you’re feeling adventurous, a drizzle of balsamic glaze or a sprinkle of crushed red pepper flakes can elevate the flavors even more.

Side Dishes

This sandwich pairs wonderfully with crispy baked fries, a refreshing mixed green salad, or even some garlicky sautéed greens like spinach or kale. For cookouts, consider classic coleslaw or grilled corn on the cob as tasty companions.

Make Ahead and Storage

Storing Leftovers

To keep your leftovers tasting fresh, store the sausages and grilled peppers and onions separately in airtight containers. Refrigerate for up to 3 days. Keeping them separate prevents the buns from getting soggy and helps preserve the vibrant flavors and textures.

Freezing

You can freeze cooked sausages and grilled veggies individually in freezer-safe containers or bags for up to 2 months. When ready, thaw overnight in the fridge before reheating to maintain the best texture and taste. It's best to freeze them without the buns to avoid sogginess.

Reheating

Reheat sausages and veggies gently in a skillet over medium heat or in the oven at 350°F until warmed through. To melt the mozzarella again, assemble your sandwich and place it briefly under the broiler or on the grill using indirect heat for 1-2 minutes. This keeps the buns fresh and flavorful.

Frequently Asked Questions:

Can I use spicy Italian sausages instead of mild?

Absolutely! Choose mild or spicy sausages based on your heat preference. Spicy sausages will add an extra kick to your sandwich, which pairs beautifully with the sweet grilled peppers.

What if I don’t have a grill basket for the veggies?

No worries! You can use a grill pan or even foil packets with holes poked in them to cook the peppers and onions. Just be sure to toss them occasionally for even cooking and to avoid burning.

Can I make this recipe vegetarian?

Yes! Substitute the Italian sausages with grilled portobello mushrooms, vegan sausage alternatives, or hearty roasted vegetables to keep the sandwich flavorful and satisfying without meat.

How do I ensure the cheese melts without burning the sandwich?

Melting the cheese over indirect medium-high heat on your grill or placing the sandwich under a broiler for just 1-2 minutes achieves a gentle melt. Avoid direct flames or prolonged heating to keep buns from burning.

Final Thoughts

This Grilled Italian Sausage and Pepper Sandwich Recipe is one of those comforting, no-fuss meals that never fails to impress. Whether you're firing up the grill for a weekend cookout or craving a quick weeknight dinner, this sandwich brings together smoky, savory, and fresh flavors in every bite. I hope these tips and ideas encourage you to make this recipe your own and enjoy the simple joy of good food shared with loved ones.