How I Found This Sandwich

I remember the first time I made what I now call my BBQ Chicken Grilled Cheese Article: it was late, the kind of rainy Tuesday that makes you crave something warm and messy. I had a cup of shredded cooked chicken left over from a rotisserie bird, a jar of thick barbecue sauce, and a stubborn loaf of sourdough. The idea felt indulgent and practical at once. If you like richer, cheesy combos, you might also enjoy my take on BBQ chicken mac and cheese, which came from the same week of improvisations.

This sandwich became my go-to when I needed comfort that didn’t require too much fuss, and it’s the sort of thing I happily make ahead for a quick lunch.

The Ingredient That Changes Everything

What makes this sing is simple and specific. I use 1 cup shredded cooked chicken, rotisserie or homemade, tossed with about 1/3 cup BBQ sauce—choose sweet, smoky, or spicy depending on your mood. For bread I like sturdy choices: sourdough, brioche, or even Texas toast works beautifully. You need 4 slices bread and 4 slices cheese; cheddar gives a sharp pull, smoked gouda brings a deeper flavor, and mozzarella melts into pure silk. I spread 2 tbsp unsalted butter or mayo on the outside of each slice so the crust crisps to that perfect golden brown. Then there are the flavorful extras I never skip: 2 tbsp caramelized onions for sweetness, 1–2 slices crispy bacon for crunch, and either pickled jalapeños or fresh herbs like parsley or cilantro to cut through the richness.

A quick note about the chicken: if you are starting from cold cooked chicken, shredding it finely and warming it gently with the BBQ sauce helps it soak up flavor without drying out. That little step matters more than you’d think.

Building the Sandwich

Prepare the BBQ Chicken by tossing the shredded cooked chicken with the BBQ sauce in a warm skillet for a few minutes until everything is glossy and the sauce clings to the meat. If you want to be exact, heat it until steam rises and you hear a quiet sizzle; that’s when the sauce starts to concentrate and taste brighter. Taste and adjust: a touch more sauce if the chicken seems dry, or a splash of vinegar if the sauce feels too sweet.

Butter the Bread generously on one side of each slice. I’ve used mayo instead of butter when I wanted an extra tang and an even crisper crust; try that trick if you have it on hand. Lay one slice butter-side down, add a slice of cheese, a layer of the BBQ chicken, the caramelized onions, bacon, pickled jalapeños or a sprinkle of fresh herbs, then top with another slice of cheese and the second piece of bread, butter-side up. Assemble the Sandwiches this way so the cheese sandwiches the saucy filling and becomes the glue that holds everything together.

A tip I like to give is to under-sauce the chicken slightly if you plan to use softer bread like brioche; it prevents sogginess. Another trick is to press the sandwich gently with the spatula as it cooks to encourage an even melt.

Getting the Grill Right

Grill to Perfection by heating a nonstick skillet or griddle over medium-low heat. I always err on the side of lower heat so the cheese melts fully before the bread goes too dark. Place the sandwich in the pan, press down slightly, and listen for that steady, satisfying sizzle. After about three to four minutes you should see a deep golden brown; flip carefully and cook the other side until it mirrors the first. How do you know when it is done right? The bread will be a crunchy, even brown and the cheese will be bubbling and stretched when you lift the sandwich with the spatula. If you see the filling leaking too much, lower the heat next time and give the cheese another minute to melt.

If you want grill marks and that outdoor aroma, finish the sandwiches on a preheated cast iron or a hot outdoor grill for thirty seconds a side. I sometimes cover the skillet with a lid for a minute to trap heat and coax a faster melt; this is especially helpful if your cheese is thick-sliced.

The Best Part About This Dish

Serve & Slice when the sandwich comes off the heat. Let it rest for a minute so the molten cheese sets just enough to avoid catastrophe on the plate. Then slice it diagonally and watch the cheese pull: that glossy ribbon is the reward for the patience. I love the contrast of textures here—the crunchy crust, the silky cheese, the tender, smoky chicken, the sweet notes from the caramelized onions, and the bright zip from pickled jalapeños or herbs. What to serve it with? A simple green salad dressed in lemon vinaigrette cuts through the richness, sweet potato fries echo the barbecue vibe, and a cold beer or iced tea makes the meal feel complete.

When you make these for a crowd, I sometimes set up a little station with extra BBQ sauce, pickles, and chopped cilantro so everyone can personalize their half.

A Note on Leftovers, Variations, and Timing

If you want to make these ahead, keep the BBQ chicken and the rest of the sandwich components separate in airtight containers and assemble just before cooking. For storage, leftover assembled sandwiches will keep in the fridge for up to two days, though they are best reheated in a skillet so the bread regains its crisp. If you find yourself with leftover shredded chicken, you can transform it into something else: roll the mixture into tortillas for a wrap, or fold it into an omelet.

Here are a couple of variations I rotate through. For a smoky, richer take swap cheddar for smoked gouda and add a pinch of smoked paprika. For a lighter, fresher riff use mozzarella, lots of cilantro, and a squeeze of lime, and skip the bacon. If you want to get playful, fold thin apple slices into the sandwich for a sweet-crisp contrast.

A few more personal tips: always preheat the pan so the butter doesn’t soak into the bread; shred the chicken finer than you think so it layers evenly; and save a little extra BBQ sauce for dipping because no one ever complains about extra sauce.

I learned one hard lesson the first time I made a dozen of these for a party: they are best hot and fresh. If you must reheat, use a skillet rather than a microwave to bring back the crunch.

Conclusion

If you want a slightly different take that focuses on shredded cheese and BBQ technique, I like the version at Cabot Creamery’s BBQ shredded chicken grilled cheese for inspiration. For a commercial-style grilled cheese that leans into classic barbecue flavors, Sonny’s has a compelling riff worth checking out at their grilled cheese page. And if you want to deepen your knowledge about making proper barbecue chicken before tossing it into a sandwich, this guide from The Paupered Chef is a great read: how to make proper barbecue chicken.

I hope this feels like the kind of recipe you could call up a friend about at dinner. It is forgiving, quick when you need it to be, and utterly satisfying.