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Grilled Italian Sausage Sandwiches with Pepper-Onion Foil Packs on a grey plate sitting atop a dark wood table.

Grilled Italian Sausage Sandwiches with Pepper-Onion Foil Packs

Grilled Italian Sausage Sandwiches with Pepper-Onion Foil Packs are an ideal, pack-up-and-go meal for cookouts and tailgate parties!
Prep Time 10 minutes
Cook Time 20 minutes
prepping the charcoal grill 25 minutes
Servings 8


  • Charcoal grill
  • chimney charcoal starter
  • charcoal lighter


  • 8 hot Italian Sausages (you can choose mild if you prefer)
  • 2 large sweet onions
  • 4 red bell peppers
  • 1 tsp coarse salt divided (or to taste)
  • 1/2 tsp freshly ground black pepper divided (or to taste)
  • 2 tbsp extra virgin olive oil
  • 8 hoagie rolls (or bratwurst buns)
  • 8 oz sliced provolone cheese (optional)


  • To make the foil packs, tear two ~12" x 20" sections of foil. Fold each in half. For each piece, roll the sides adjacent to the fold tightly 3–4 times to make a pouch.
  • Mix the sliced onions and peppers. Divide approximately between the two foil pouches. Add 1/2 tsp of salt, 1/4 tsp of freshly ground black pepper, and 1 tbsp of oil to each pouch. Fold the top of the pouch several times to seal. Refrigerate until use.
  • Prepare charcoal grill for indirect heat. When the coals are hot and completely ashed over (white), add the sausages directly over the coals. Place the pepper-onion packs on the indirect heat side of the grill.
  • Grill the sausages for 3–5 minutes each on 2 sides, or until browned (check to be sure they don't burn; see Recipe Note #1). Continue grilling, turning as necessary, until thoroughly cooked, an additional 8–9 minutes (total 15–18 minutes) to cook through. If you'd like to toast your rolls, move the sausages to indirect heat and toast the bread until lightly browned.
  • To assemble the sandwiches, lay 1–2 slices of provolone cheese (if using) on the bottom of the roll. Add one hot sausage and ~1/2 cup of the pepper-onion mixture (see Recipe Note #2).



  1. If your fire is too hot, move the sausages to indirect heat. Turn every few minutes until thoroughly cooked. 
  2. Be very careful when opening the foil packs to prevent steam burns.