Cooking sausage on the barbecue is a delicious way to add flavor and variety to your grilling. However, it can be tricky to get the timing just right. Undercook your sausage and it will be tough and rubbery. Cook it too long and your sausage will be dry and shriveled. So how long should you cook sausage on the BBQ? Follow this guide for tips on perfectly grilled sausage.
Choosing the Right Sausage
The first step is selecting the right type of sausage. Here are some of the most common options:
Pork Sausage
This classic option is made from ground pork and seasoning. Pork sausage comes in links, patties, or bulk. It can be raw or pre-cooked. Raw pork sausage needs thorough cooking to 165°F. Pre-cooked just needs warming.
Chicken or Turkey Sausage
Made from ground poultry, these are a leaner alternative to pork sausage. Cook to 165°F.
Bratwurst
These fat German sausages are usually pork-based. Grill until the internal temperature reaches 160°F.
Italian Sausage
Flavored with fennel, garlic, and paprika, Italian sausage can be raw or pre-cooked. Follow temperature guidelines accordingly.
Plant-based Sausage
Veggie sausages are a good option for vegetarians and vegans. Always cook thoroughly.
No matter the variety, quality fresh sausage is key. Look for sausages without excess fat or seasoning oozing out – this is a sign they are poorly made. Local butcher sausages tend to be higher quality than generic grocery store options.
Hot Dogs and Smoked Sausage
Hot dogs, smoked sausages, kielbasa, and cervelat can all be cooked a bit differently than fresh raw sausage. These sausages are pre-cooked during processing, so they just need to be heated through on the grill. Cook hot dogs and smoked sausages until lightly charred, 5-8 minutes.
Sausage Thickness
The thickness of your sausage will impact cooking times. Here are some guidelines based on size:
- Thin sausages less than 1 inch diameter – Grill for 4-7 minutes per side.
- Standard sausages 1 – 1.5 inches thick – Cook 7-15 minutes per side.
- Thick gourmet sausages over 2 inches – Grill 15-22 minutes per side.
- Sausage links – Cook 10-15 minutes, turning occasionally.
- Sausage patties – Grill 8-12 minutes total, flipping halfway.
- Italian sausage rings – Grill 5 minutes per side.
Prepare Sausage Properly
To prevent your sausage from bursting open on the grill, follow these tips:
- Use a grill basket to keep sausages contained.
- Parboil or poach raw sausages for 1-2 minutes before grilling.
- Pierce sausages several times with a fork before cooking.
- Brush or spray oil on the sausage to prevent sticking.
- Start grilling with gentler indirect heat, then finish over higher heat for browning.
Check Internal Temperatures
The best way to ensure your sausage is properly cooked and safe to eat is to use an instant-read meat thermometer. Insert the probe into the thickest part of the sausage. Here are the recommended safe internal temperatures:
- Fresh pork sausage – 160°F
- Fresh poultry sausage – 165°F
- Bratwurst – 160°F
- Smoked sausage, kielbasa – 140°F
- Hot dogs – 135°F
- Pre-cooked sausage – 135°F
If your sausage registered a lower temp, return it to the grill for additional cooking.
Doneness Cues Other Than Temperature
If you don’t have a meat thermometer handy, look for these visible signs your sausage is cooked through:
- Firm, springy texture without any spongy parts.
- Plump appearance, not shriveled or deflated.
- Light external browning.
- Juices run clear.
Err on the side of overcooking until you are comfortable determining doneness.
Common Grilling Mistakes
Avoid these pitfalls when cooking your sausage:
- Not heating grill adequately – Use medium-high heat so sausages sizzle and brown.
- Charring exterior before interior is cooked – Use gentler indirect heat first.
- Puncturing casings – Prick before grilling or use a grill basket.
- Overcrowding grill – Don’t overload the grates.
- Poor sanitation – Wash hands, utensils, prep surfaces before and after.
- Eating undercooked sausage – Use a food thermometer and cook to proper temp.
Serving Grilled Sausage
Your perfectly barbecued sausage deserves proper accompaniments. Consider these ideas:
- Sausage sandwiches – Serve on buns or rolls with favorite toppings.
- Alongside other grilled foods – Try sausage with shrimp, corn, potatoes, etc.
- In kebabs or skewers – Alternate with veggies in a shish kebab.
- On a cheese board – Offer an assortment of smoked sausages and mustards.
- With peppers and onions – A classic festival food pairing.
- In pasta, eggs, pizza, etc – Chop up cooked sausage to add big flavor.
- With sauces and mustards – Spicy brown mustard is a standard condiment.
Get creative with recipes and toppings to take your grilled sausage to the next level.
Sausage Safety Tips
Proper handling and cooking is key to enjoying sausage safely:
- Refrigerate sausage at 40°F or below until ready to grill. Use within 1-2 days of purchase.
- Always wash hands, utensils, and surfaces that have touched raw sausage to prevent bacteria spread.
- Cook sausage thoroughly to safe internal temperature (see above).
- Never partially cook then finish later – this can breed bacteria.
- Serve grilled sausage immediately or keep warm at 140°F+ until serving.
- Refrigerate cooked leftovers within 2 hours and use within 3-4 days. Reheat to 165°F before eating.
With the proper techniques, grilled sausage cooked outside on the barbecue makes for mouthwatering summertime fare. Follow this guide for tips on selecting, preparing, cooking, and serving sausage so your BBQ is a sizzling success.
Frequently Asked Questions About Grilling Sausage
Grilling sausage may seem straightforward, but there are some common questions that come up. Here are answers to some of the most frequently asked queries:
What is the best way to cook sausage on the grill?
Use moderate, indirect heat around 350-450°F first to cook sausage through without burning the exterior. Then, finish with higher direct heat for 2-3 minutes per side to get crispy grill marks and caramelization. Use a meat thermometer to confirm safe internal temperature.
Should I grill sausage links or patties?
Sausage links are the traditional shape, which allow fats to baste the sausage as it cooks. Patties offer more surface area for browning. Choose based on your preferences – both work well. Make sure sausage is not overcrowded.
How do I stop sausage from exploding on the grill?
Prick sausages all over with a fork before grilling to allow steam to escape and prevent bursting. Place on indirect heat first. Also, poach or parboil raw sausage briefly before putting on the barbecue.
What are the best seasonings for sausage on the grill?
Popular spice rubs for sausage include brown sugar, chili powder, cumin, garlic, mustard, salt, pepper, sage, and red pepper flakes. Avoid excessive sugar that may burn. Brush on oil or mustard-based sauces toward the end for flavor.
Can I use frozen sausage on the BBQ?
Yes, frozen sausage links, patties or bulk sausage can all be cooked directly on the grill, but they require more time to defrost and cook through. Thaw first for faster grilling. Partially grilling then finishing later is unsafe.
Should I flip sausage often while grilling?
Occasional flipping is helpful to promote even cooking, but don’t flip too often. Let the sausage develop crust before moving it. Use tongs for links; spatulas for patties. Hot dogs can roll while cooking – use low direct heat.
How do I reheat grilled sausage safely?
To reheat cooked sausage, use a grill, skillet, oven, or microwave to quickly heat to 165°F. Slice and reheat in barbecue sauce, peppers, or on buns to prevent drying out. Do not partially cook, let sit, then finish later – this is unsafe.
Grilling sausage requires paying attention to factors like thickness, preparation, temperature, and handling for ideal results. Follow proper safety measures as well. With the right techniques, you’ll be rewarded with juicy, flavorful sausage off the barbecue.
Conclusion
Grilling sausage is an easy way to add savory flavor to any barbeque. Different types of sausages require slightly different approaches, but as a general rule, indirect heat first, followed by higher direct heat for browning produces the best results. Cook raw sausage to 160°F, and smoked or pre-cooked varieties to 135°F for food safety. With the proper prep, heating, and handling, juicy grilled sausage can be enjoyed all summer long. Follow this guide to get your sausage sizzling to perfection.