Grilled Sausage and Pepper Hoagies with Flame-Caramelized Onions

Quick Recipe Version (TL;DR)

• Yield: 4 hoagies (4 servings)
• Prep Time: 20 minutes
• Cook Time: 30 minutes
• Total Time: 50 minutes

Quick Ingredients

• 4 Italian sausage links (4–5 oz / 115–140 g each)
• 3 bell peppers, seeded and sliced into 1-inch strips
• 2 large yellow onions, sliced into 1/2-inch rounds
• 3 tbsp olive oil, plus 2 tbsp softened butter or more oil for rolls
• 1 1/4 tsp kosher salt, 3/4 tsp black pepper
• 1 tsp dried oregano, 1/2 tsp dried basil, pinch red pepper flakes (optional)
• 1/2 cup (120 ml) water or beer (for grilling sausages)
• 4 hoagie rolls, 6-inch (15 cm), split but hinged
• 4 slices provolone or mozzarella (optional)
• Mayonnaise and Dijon or whole-grain mustard (optional, for serving)

Do This

• 1) Preheat grill to medium-high (about 400–425°F / 205–220°C). Oil grates.
• 2) Toss peppers and onion rounds with olive oil, salt, pepper, oregano, basil, and red pepper flakes.
• 3) Grill onion rounds directly over the flame 12–15 minutes, turning often, until deeply caramelized and tender; grill peppers 8–10 minutes until blistered.
• 4) Season sausages with a pinch of salt and pepper, then grill 10–12 minutes, turning, adding 1/2 cup water or beer to create steam and prevent burning.
• 5) Butter hoagie rolls and toast cut-side down on grill 1–2 minutes; add cheese to rolls and close grill briefly to melt.
• 6) Roughly chop grilled onions, slice sausages, and pile into rolls with peppers. Add condiments if using and serve hot.

---

Why You’ll Love This Recipe

• Flame-caramelized onions bring a sweet, smoky depth that balances the richness of the sausage.
• Everything is done on the grill, so there is minimal cleanup and maximum flavor.
• Easy to scale up for game day, backyard parties, or a casual family dinner.
• Flexible toppings and sausage styles let you make it mild, spicy, cheesy, or extra veggie-loaded.

Grocery List

• Produce: 3 bell peppers, 2 large yellow onions
• Dairy: Butter, provolone or mozzarella cheese (optional), mayonnaise (optional)
• Pantry: Italian sausage links, hoagie rolls, olive oil, kosher salt, black pepper, dried oregano, dried basil, crushed red pepper flakes, Dijon or whole-grain mustard (optional), beer or water for grilling

Full Ingredients

For the Grilled Onions and Peppers

• 3 bell peppers (red, yellow, or orange), seeded and cut into 1-inch-wide strips
• 2 large yellow or sweet onions, peeled and sliced into 1/2-inch-thick rounds (try to keep the rounds intact)
• 3 tbsp olive oil
• 1 tsp kosher salt
• 1/2 tsp freshly ground black pepper
• 1 tsp dried oregano
• 1/2 tsp dried basil
• 1/4 tsp crushed red pepper flakes (optional, for heat)

For the Sausages

• 4 Italian sausage links (mild or hot), 4–5 oz (115–140 g) each
• 1/4 tsp kosher salt
• 1/4 tsp freshly ground black pepper
• 1/2 cup (120 ml) water or beer (for grilling, optional but recommended)

For the Hoagies

• 4 hoagie or sub rolls, 6-inch (15 cm), split lengthwise but not cut all the way through
• 2 tbsp softened butter or olive oil (for toasting the rolls)
• 4 slices provolone or mozzarella cheese (optional, for melty hoagies)
• 2 tbsp mayonnaise (optional)
• 2 tbsp Dijon or whole-grain mustard (optional)

Step-by-Step Instructions

Step 1: Preheat the Grill and Prep the Vegetables

Preheat your grill to medium-high heat, aiming for 400–425°F (205–220°C). If you are using a charcoal grill, build a two-zone fire with one side hotter for direct grilling and one side cooler for finishing.

While the grill heats, slice the bell peppers into 1-inch-wide strips. Peel the onions and slice them into 1/2-inch-thick rounds. Try to keep the onion rounds intact so they are easier to grill directly over the flame.

Place the peppers and onion rounds in a large bowl or on a baking sheet. Drizzle with 3 tbsp olive oil, then sprinkle on 1 tsp kosher salt, 1/2 tsp black pepper, 1 tsp dried oregano, 1/2 tsp dried basil, and 1/4 tsp red pepper flakes (if using). Toss gently until everything is evenly coated.

Step 2: Season the Sausages

Pat the sausage links dry with a paper towel. Lightly prick each sausage a few times with the tip of a knife or a skewer (do not overdo it or you will lose too many juices). Season them with 1/4 tsp kosher salt and 1/4 tsp black pepper, rubbing the seasoning over the casings so it sticks.

Set the sausages aside at room temperature while you start the vegetables. This helps them cook more evenly on the grill.

Step 3: Flame-Carmelize the Onions Directly Over the Heat

Clean and oil your grill grates well so the onions do not stick. Place the seasoned onion rounds directly over the hotter side of the grill, right over the flame or coals. Arrange them carefully so they lie flat. If you have a grill basket or wide skewers, you can use these to help keep the rings together, but still keep them directly over the flame.

Grill the onion rounds for 12–15 minutes total, turning every 2–3 minutes with tongs. You want deep caramelization and some char on the edges, but not a completely burnt surface. Move any pieces that are browning too quickly to a slightly cooler area of the grill. The onions are done when they are softened through, with a deep golden-brown color and some blackened spots.

Transfer the caramelized onions to a plate or cutting board to rest. They will continue to soften slightly as they sit.

Step 4: Grill the Peppers Until Blistered and Tender

Once the onions are underway (or finished), add the bell pepper strips directly to the grill grates over medium-high heat. Lay them across the grates so they do not fall through. Grill for 8–10 minutes total, turning occasionally, until the skins are lightly charred and blistered in spots and the peppers are tender but not mushy.

If any peppers threaten to burn, move them to the cooler side of the grill to finish cooking gently. Transfer the grilled peppers to the same plate as the onions when they are done.

Step 5: Grill the Sausages

Place the seasoned sausages on the hotter side of the grill. Grill for 3–4 minutes per side, turning as they brown, until they are well-marked all around (about 8–10 minutes total).

Reduce the heat slightly (or move the sausages to the cooler side of the grill). Carefully pour 1/2 cup water or beer into a disposable aluminum pan or a small grill-safe skillet and set it directly on the grill. Nestle the sausages into this liquid, close the lid, and let them simmer and gently finish cooking for another 4–6 minutes, until the internal temperature reaches 160°F (71°C).

Remove the sausages from the liquid and let them rest on a plate for 5 minutes. Resting keeps them juicy when you slice them for the hoagies.

Step 6: Chop the Onions and Peppers, and Toast the Rolls

While the sausages rest, roughly chop the grilled onion rounds into bite-size pieces. You can leave the peppers as strips or cut them shorter if you prefer. Toss the onions and peppers together so every bite gets a mix of sweet-caramelized onions and smoky peppers.

Brush the cut sides of the hoagie rolls with softened butter or olive oil. Place the rolls cut-side down on the grill over medium heat and toast for 1–2 minutes until lightly browned and crisp around the edges.

If you are using cheese, flip the rolls cut-side up, lay a slice of provolone or mozzarella inside each, close the grill lid, and let the cheese melt for 1–2 minutes. Watch carefully so the bottoms do not burn.

Step 7: Assemble the Sausage and Pepper Hoagies

Slice the rested sausages on a slight diagonal into 1/2-inch-thick pieces. You can also leave them whole if you prefer a classic single-link hoagie, but sliced sausage gives you more surface area and mingles better with the peppers and onions.

If using, spread a thin layer of mayonnaise and/or Dijon or whole-grain mustard inside each toasted roll. Pile a generous layer of the grilled onions and peppers into the bottom of each roll, then nestle the sliced (or whole) sausages on top. Spoon any extra juices over the filling.

Close the hoagies slightly to hold everything in, and serve immediately while everything is hot and the cheese is melty.

Pro Tips

• Keep onion rounds intact: Slice onions thick and handle them gently when flipping. A wide spatula or flat metal spatula can help keep the rounds from breaking apart over the flame.
• Use two heat zones: High heat is perfect for getting that deep caramelization and char, but a cooler zone lets you finish cooking without burning. This is especially helpful for the onions and sausages.
• Grill basket insurance: If you are worried about losing onion rings or pepper strips, use a grill basket. You will still get direct flame contact while keeping everything contained.
• Do not rush the onions: Proper caramelization over the flame takes a bit of time. Let them get deeply golden with some char; that flavor is what balances the richness of the sausage.
• Warm the rolls, do not scorch: Rolls toast quickly on a hot grill. Stay close and check after 1 minute so they turn golden and crisp, not burnt.

Variations

• Cheesy provolone hoagies: Layer 1–2 slices of provolone or mozzarella into each toasted roll and let it melt completely before adding the sausages and peppers for a gooey, deli-style sandwich.
• Extra-spicy version: Use hot Italian sausages, add the red pepper flakes to the veggies, and finish with a drizzle of your favorite hot sauce before serving.
• Skillet finish: After grilling, toss sausages, onions, and peppers together in a cast-iron skillet on the grill with a splash of beer or broth. Let everything bubble for a few minutes to mingle the flavors, then scoop into rolls.

Storage & Make-Ahead

Store leftover grilled sausage, onions, and peppers (without the rolls) in an airtight container in the refrigerator for up to 3 days. Reheat gently in a skillet over medium heat with a splash of water or broth until hot. Toast fresh hoagie rolls just before serving to bring back the crisp exterior.

You can prep the vegetables earlier in the day by slicing and seasoning them, then keeping them covered in the refrigerator for up to 8 hours. Let them sit at room temperature for 15–20 minutes before grilling. The sausages can also be seasoned in advance and refrigerated. For freezing, your best bet is to freeze the cooked sausage and vegetable mixture (up to 2 months), then thaw overnight in the fridge and reheat on the stovetop or in a covered skillet on the grill.

Nutrition (per serving)

Approximate for 1 hoagie (including sausage, peppers, onions, roll, about 1/2 tbsp butter or oil on the roll, and 1 slice provolone, without condiments): about 780 calories; 34 g protein; 48 g fat; 47 g carbohydrates; 4 g fiber; 7 g sugar; 1,450 mg sodium. Actual values will vary based on specific sausage brand, roll size, and optional condiments.