Mouthwatering Grilled Pork Chop Sandwich

There’s something about a good sandwich that just hits different on a weekend afternoon. Not your boring cold cuts from the deli counter, but something with a little char, a little smoke, and a whole lot of flavor. That’s where this grilled pork chop sandwich comes in.

I know what you’re thinking – pork chops on a sandwich? Trust me on this one. When you grill up a thick-cut chop until it’s juicy and season it just right, then pile it on a toasted brioche bun with crispy fried onions and a smear of mayo, you’ve got yourself a meal worth firing up the grill for.

The best part? This isn’t some complicated restaurant recipe. You’re basically making a really good pork chop, throwing together some crunchy onion rings, and assembling it all like you would any other sandwich. Easy enough for a weeknight, but special enough that everyone will think you spent way more time on it than you actually did.

What Kind of Pork Chops Should I Use?

For this sandwich, boneless pork chops are the way to go since they’re easier to eat and fit better on a bun. You’ll want chops that are about ¾ to 1 inch thick – any thinner and they’ll dry out on the grill, any thicker and they won’t cook evenly. Center-cut chops tend to be the most tender and have a good amount of meat, making them perfect for sandwiches. If you can only find bone-in chops at the store, you can still use them, just be aware that the cooking time might be a bit longer and you’ll need to work around the bone when eating your sandwich.

Options for Substitutions

This sandwich is pretty straightforward, but here are some swaps you can make if needed:

• Boneless pork chops: You can use bone-in pork chops if that’s what you have – just adjust your grilling time since they’ll take a bit longer to cook through. Chicken breasts also work well if you want to switch up the protein.
• Hamburger buns: Any sandwich bun works here – try kaiser rolls, ciabatta rolls, or even sliced sourdough bread for a different texture.
• Dad’s All Purpose rub: Don’t have this specific rub? Make your own blend with paprika, garlic powder, onion powder, salt, and pepper, or use your favorite store-bought seasoning mix.
• Iceberg lettuce: Swap in romaine, butter lettuce, or even fresh spinach leaves. Any crisp lettuce will add that nice crunch to your sandwich.
• Mayo: If you’re not a mayo fan, try mustard, ranch dressing, or even a simple garlic aioli for some extra flavor.
• All purpose flour: You can skip the flour coating entirely for a lighter sandwich, or use panko breadcrumbs for extra crunch. If you need a gluten-free option, cornstarch works well too.

Watch Out for These Mistakes While Grilling

The biggest mistake when grilling pork chops is cooking them all the way to 165°F, which leaves you with dry, chewy meat – instead, pull them off the grill at 140°F and let them rest for 5 minutes, as the temperature will rise to a safe 145°F while keeping the meat juicy.

Another common error is not pounding the pork chops to an even thickness before grilling, which causes thinner parts to overcook while thicker sections stay undercooked.

When frying the onions, make sure your oil is actually at 375°F using a thermometer – if it’s too cool, the onions will absorb excess oil and turn greasy instead of crispy, and if it’s too hot, they’ll burn on the outside before cooking through.

Finally, don’t skip the resting period after grilling, as cutting into the pork chops immediately causes all the juices to run out onto your cutting board instead of staying in the meat where they belong.

What to Serve With Grilled Pork Chop Sandwich?

These sandwiches are hearty enough to be a meal on their own, but a side of crispy fries or potato chips is always a good call for that classic sandwich-and-sides combo. Coleslaw is another great option since the cool, crunchy slaw balances out the warm, savory pork really nicely. If you want something lighter, try a simple cucumber and tomato salad or some pickles on the side – the tangy crunch cuts through the richness of the mayo and pork. For a cookout-style meal, add some baked beans or corn on the cob to round everything out.

Storage Instructions

Store: If you have leftover grilled pork chops, keep them separate from the buns and toppings in an airtight container in the fridge for up to 3 days. Store the lettuce, onions, and mayo separately so everything stays fresh and the bread doesn’t get soggy.

Reheat: Warm up the pork chops in a skillet over medium heat for a few minutes on each side, or microwave them for about 30-45 seconds. You can also toast the buns lightly before assembling your sandwich again to bring back that fresh-made taste.

Estimated Nutrition

Estimated nutrition for the whole recipe (without optional ingredients):

• Calories: 1450-1700
• Protein: 90-110 g
• Fat: 45-55 g
• Carbohydrates: 160-180 g

Ingredients

For the fried onions:

• 1 large onion (thinly sliced into 1/8-inch rings)
• 1 1/4 cups King Arthur all-purpose flour
• 2 1/2 tbsp Dad’s All Purpose seasoning

For the grilled pork:

• 4 thick-cut bone-in pork chops
• 2 tbsp McCormick Grill Mates Montreal Steak seasoning
• 1/2 tsp smoked paprika
• 1/2 cup BBQ sauce for glazing

For the assembly:

• 4 brioche buns (toasted)
• 1 cup iceberg lettuce (shredded into 1/4-inch strips)
• 4 tbsp Hellmann’s mayonnaise

Step 1: Prepare Mise en Place and Season the Pork

• 1 large onion
• 4 thick-cut bone-in pork chops
• 2 tbsp McCormick Grill Mates Montreal Steak seasoning
• 1/2 tsp smoked paprika

Slice the onion into thin 1/8-inch rings and set aside.

Pat the pork chops dry with paper towels—this helps them brown better on the grill.

In a small bowl, combine the Montreal Steak seasoning and smoked paprika, then generously season both sides of each pork chop.

Let them sit at room temperature for 5-10 minutes while you prepare the other components.

I like to season the meat early so the flavors penetrate the surface before cooking.

Step 2: Bread and Fry the Onions

• sliced onions from Step 1
• 1 1/4 cups King Arthur all-purpose flour
• 2 1/2 tbsp Dad’s All Purpose seasoning

Toss the sliced onions in a bowl with the flour and Dad’s All Purpose seasoning until evenly coated.

Heat oil in a cast iron skillet on your grill to 375°F.

Working in batches if needed, carefully add the floured onions to the hot oil and fry for 4-5 minutes, stirring occasionally, until they’re golden brown and crispy.

Remove with a slotted spoon and drain on paper towels.

Keep them warm while you cook the pork chops.

Step 3: Grill and Glaze the Pork Chops

• seasoned pork chops from Step 1
• 1/2 cup BBQ sauce for glazing

Place the seasoned pork chops directly on a preheated grill at medium-high heat (about 375°F).

Grill for 4-5 minutes on the first side without moving them, then flip and cook for another 4-5 minutes.

Once both sides have a nice sear, brush generously with BBQ sauce on both sides, then continue cooking for 1-2 minutes per side until the internal temperature reaches 140°F (measured with a meat thermometer at the thickest part, away from the bone).

The glaze will caramelize slightly, adding great flavor and a nice exterior.

Step 4: Rest the Meat and Toast the Buns

• cooked pork chops from Step 3
• 4 brioche buns

Transfer the glazed pork chops to a clean plate and let them rest for 5 minutes—this allows the juices to redistribute throughout the meat, keeping it tender and juicy.

While the pork rests, place the brioche buns cut-side down on the grill for 1-2 minutes until they’re lightly toasted and golden.

I prefer toasting buns on the grill for a subtle smoky flavor rather than in a toaster.

Step 5: Assemble the Sandwiches

• toasted brioche buns from Step 4
• 4 tbsp Hellmann’s mayonnaise
• 1 cup iceberg lettuce
• rested pork chops from Step 4
• crispy fried onions from Step 2

Spread 1 tablespoon of mayonnaise on the bottom bun of each sandwich.

Top with a small handful of shredded lettuce, then place a rested pork chop on top.

Pile a generous portion of the crispy fried onions from Step 2 onto each pork chop, then crown with the toasted top bun.

Serve immediately while the pork is still warm and the buns are still crispy.

Mouthwatering Grilled Pork Chop Sandwich

Delicious Mouthwatering Grilled Pork Chop Sandwich recipe with step-by-step instructions.

Print Recipe Pin Recipe

Prep Time 10 minutes mins

Cook Time 25 minutes mins

Total Time 37 minutes mins

Servings: 4 sandwiches

Calories: 1575

Ingredients Method

Ingredients

  

For the fried onions

• 1 large onion (thinly sliced into 1/8-inch rings)
• 1 1/4 cups King Arthur all-purpose flour
• 2 1/2 tbsp Dad's All Purpose seasoning

For the grilled pork

• 4 thick-cut bone-in pork chops
• 2 tbsp McCormick Grill Mates Montreal Steak seasoning
• 1/2 tsp smoked paprika
• 1/2 cup BBQ sauce for glazing

For the assembly

• 4 brioche buns (toasted)
• 1 cup iceberg lettuce (shredded into 1/4-inch strips)
• 4 tbsp Hellmann's mayonnaise

Method

 

1. Slice the onion into thin 1/8-inch rings and set aside. Pat the pork chops dry with paper towels—this helps them brown better on the grill. In a small bowl, combine the Montreal Steak seasoning and smoked paprika, then generously season both sides of each pork chop. Let them sit at room temperature for 5-10 minutes while you prepare the other components. I like to season the meat early so the flavors penetrate the surface before cooking.
2. Toss the sliced onions in a bowl with the flour and Dad's All Purpose seasoning until evenly coated. Heat oil in a cast iron skillet on your grill to 375°F. Working in batches if needed, carefully add the floured onions to the hot oil and fry for 4-5 minutes, stirring occasionally, until they're golden brown and crispy. Remove with a slotted spoon and drain on paper towels. Keep them warm while you cook the pork chops.
3. Place the seasoned pork chops directly on a preheated grill at medium-high heat (about 375°F). Grill for 4-5 minutes on the first side without moving them, then flip and cook for another 4-5 minutes. Once both sides have a nice sear, brush generously with BBQ sauce on both sides, then continue cooking for 1-2 minutes per side until the internal temperature reaches 140°F (measured with a meat thermometer at the thickest part, away from the bone). The glaze will caramelize slightly, adding great flavor and a nice exterior.
4. Transfer the glazed pork chops to a clean plate and let them rest for 5 minutes—this allows the juices to redistribute throughout the meat, keeping it tender and juicy. While the pork rests, place the brioche buns cut-side down on the grill for 1-2 minutes until they're lightly toasted and golden. I prefer toasting buns on the grill for a subtle smoky flavor rather than in a toaster.
5. Spread 1 tablespoon of mayonnaise on the bottom bun of each sandwich. Top with a small handful of shredded lettuce, then place a rested pork chop on top. Pile a generous portion of the crispy fried onions from Step 2 onto each pork chop, then crown with the toasted top bun. Serve immediately while the pork is still warm and the buns are still crispy.