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Triple Cheese Bacon Explosion Sandwich

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Yields: 1 monumental sandwich (easily serves 2-4 people)
Prep Time: 25 minutes
Cook Time: 35 minutes
Total Time: 60 minutes
Intensity: Intermediate – This recipe involves multi-tasking, managing a hot skillet, and careful assembly. The results are well worth the focus.

Ingredients

For the Bacon Weave & Sausage Layer:

  • 1 lb regular-cut bacon (about 12-14 slices)

  • 1 lb ground Italian sausage (mild or hot, based on preference)

  • 1 teaspoon garlic powder

  • 1 teaspoon smoked paprika

For the Triple Cheese Filling:

  • 1 cup shredded sharp cheddar cheese

  • 1 cup shredded Monterey Jack cheese

  • 4 oz (1/2 block) cream cheese, softened

  • 2 tablespoons finely chopped chives or green onions

For the Signature Sauce:

  • 1/2 cup mayonnaise

  • 2 tablespoons your favorite barbecue sauce

  • 1 tablespoon maple syrup

  • 1 teaspoon Dijon mustard

  • 1 teaspoon hot sauce (optional)

For Assembly:

  • 1 large, high-quality brioche bun or a small loaf of ciabatta, halved

  • 2 tablespoons butter, softened

  • 1 cup fresh arugula or shredded iceberg lettuce (for crunch and freshness)

Equipment You’ll Need

  • Large skillet (cast iron preferred)

  • Baking sheet

  • Parchment paper

  • Mixing bowls

  • Spatula and tongs

Instructions

Step 1: Construct the Bacon Explosion Base

This is where the magic begins. The bacon weave is the structural heart of the sandwich.

  1. Create the Weave: Lay out a large piece of parchment paper on your counter. Arrange 6-7 slices of bacon vertically, side-by-side, touching but not overlapping. Fold every other bacon slice back halfway. Take one new slice of bacon and lay it horizontally across the unfolded slices. Unfold the vertical slices back down. Now, fold back the other set of vertical slices. Lay a second horizontal slice of bacon next to the first. Repeat this weaving process until you have a square bacon lattice.

  2. Prepare the Sausage: In a bowl, combine the ground Italian sausage, garlic powder, and smoked paprika. Mix with your hands until well-combined.

  3. Form the Layer: Place the sausage mixture on top of the bacon weave. Using your hands or a spatula, press the sausage into an even, rectangular layer, leaving a 1-inch border of bacon clear on all sides.

Step 2: Create the Molten Cheese Core

  1. Mix the Cheeses: In a separate bowl, combine the shredded cheddar, Monterey Jack, softened cream cheese, and chives. Use a fork to mix until the cream cheese is evenly distributed and the cheeses are well-integrated.

  2. Form the Log: Take the cheese mixture and form it into a tight, log-like shape, roughly the length of your bun. Place this cheese log horizontally across the center of the sausage-covered bacon weave.

Step 3: The Roll and The Bake

  1. Roll It Up: Using the parchment paper to help you, carefully lift the edge of the bacon weave and roll it over the cheese log, tucking it in tightly. Continue rolling, using the parchment to guide you, until the entire bacon weave is wrapped around the sausage and cheese, forming a massive, sealed log.

  2. Seam Side Down: Place the log seam-side down on a baking sheet (you can keep it on the parchment for easy cleanup).

  3. Bake to Perfection: Preheat your oven to 375°F (190°C). While it heats, you can partially cook the log. Bake for 25-30 minutes, or until the bacon is crispy and the internal temperature of the sausage reaches 160°F (71°C). For extra crispiness, you can finish it under the broiler for the last 1-2 minutes, watching closely to prevent burning.

Step 4: Prepare the Supporting Cast

While the bacon explosion is baking:

  1. Make the Signature Sauce: Whisk together the mayonnaise, barbecue sauce, maple syrup, Dijon mustard, and hot sauce (if using) in a small bowl. Set aside.

  2. Toast the Bun: Spread the softened butter on the inside of your brioche bun or ciabatta. In the last 5 minutes of the bacon log’s cooking time, place the bun, buttered-side-up, in the oven to toast until golden brown.

  3. Cook Extra Bacon: Quickly pan-fry the remaining 6-7 slices of bacon until very crispy. We will use these for an extra textural layer in the final assembly.

Step 5: The Grand Assembly

This is where it all comes together. Assemble with purpose!

  1. Sauce the Base: Place the bottom half of the toasted bun on your serving board. Slather a generous amount of the signature sauce onto the bun.

  2. Green Foundation: Top with a bed of fresh arugula or shredded lettuce. This provides a crucial fresh, peppery contrast to the rich meat and cheese.

  3. The Main Event: Using two spatulas for support, carefully transfer the entire baked bacon explosion log onto the bed of greens.

  4. The Crispy Crown: Crumble or lay the extra strips of crispy cooked bacon on top of the hot log.

  5. Final Drizzle and Cap: Drizzle more of the signature sauce over the bacon. Place the top bun on the summit of your creation.

Step 6: Serve and Conquer

  1. The Rest: Let the sandwich rest for 2-3 minutes. This allows the cheeses to settle slightly, making it easier to cut.

  2. The Cut: Using a very sharp, serrated knife, carefully slice the sandwich in half. Be prepared for a glorious, cheesy pull. Serve immediately with plenty of napkins and a sense of accomplishment.

The Last of the Recipe: Storage & Reheating

  • Storing Leftovers: It is highly unlikely you will have leftovers. However, if you do, wrap any remaining sandwich or the bacon log itself tightly in plastic wrap and store in the refrigerator for up to 2 days.

  • Reheating: To recapture the magic, reheating in an air fryer or oven is best. Do not use a microwave, as it will make the bacon and bun soggy. Place slices or the log on a baking sheet and reheat at 350°F (175°C) for 10-15 minutes, or until warmed through and the exterior is crispy again.

Nutrition Information

*Please note: The following nutrition information is a rough estimate for 1/4 of the entire sandwich and can vary greatly based on specific ingredients and brands used.*

  • Serving Size: 1/4 of the sandwich

  • Calories: ~1,150 kcal

  • Total Fat: 95g

  • Saturated Fat: 35g

  • Cholesterol: 220mg

  • Sodium: 2,100mg

  • Total Carbohydrates: 35g

  • Dietary Fiber: 1g

  • Sugars: 12g

  • Protein: 45g

Chef’s Notes & Customizations

  • The Cheese Pull Secret: The combination of melting cheeses (cheddar, Jack) with the creamy, sticky nature of the cream cheese is what creates that iconic, photogenic cheese pull.

  • Bacon Weave Patience: Take your time with the weave. A tight, well-constructed weave is what holds the entire structure together during cooking and eating.

  • Spice It Up: Use spicy Italian sausage and add a tablespoon of chopped jalapeños to the cheese mixture for a fiery kick.

  • The “Inside-Out” Version: For a less structured but equally delicious approach, you can simply cook the sausage as patties and the bacon as strips. Assemble the sandwich by stacking a sausage patty, a layer of the cheese mixture, crispy bacon, and another patty on the toasted bun. It’s messier but faster.

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