• Italian Sausages: Choose hot, sweet, or a combination of both for a balanced flavor profile.
• Onion: A large sweet onion works best, providing a lovely caramelized sweetness.
• Bell Peppers: A mix of red, yellow, and orange bell peppers adds vibrant color and varying degrees of sweetness. Green bell peppers are also an option for a slightly more bitter note.
• Hot Dog or Sausage Buns: Opt for sturdy buns that can hold up to the juicy sausages and generous toppings.
• Olive Oil: Essential for sautéing the vegetables and preventing sticking.
• Salt, Pepper, Garlic Powder (SPG): Our preferred seasoning blend for a simple yet effective flavor boost.

For precise measurements and detailed quantities, please refer to the comprehensive recipe card below.

1. Step 1: Prepare Your Vegetables. Begin by washing and slicing your bell peppers and onions into long, uniform strips. Aim for slices that are about ¼ to ½ inch thick. This ensures they cook evenly and can be easily piled onto your sausages. Avoid chopping them too finely, as they might fall through the grill grates or become mushy.

2. Step 2: Preheat Your Grill and Cast Iron. Preheat your grill to a medium-high temperature, aiming for 350-400°F. Once preheated, place a cast iron pan or skillet directly on the grill grates. Allowing the cast iron to heat up with the grill ensures even cooking for your vegetables and helps achieve that desirable caramelization.

3. Step 3: Prepare the Sausages for Grilling. Carefully place your Italian sausages directly onto the hot grill grates. Before they start cooking rapidly, take a toothpick or a sharp knife and poke 3-4 small holes in each sausage. This crucial step allows excess fat to render out slowly, preventing the sausages from violently splitting or bursting during cooking, ensuring they remain juicy and intact.

4. Step 4: Cook the Onions and Peppers. Once your cast iron skillet is hot, add a drizzle of olive oil, then toss in your sliced onions and bell peppers. Season generously with salt, pepper, and garlic powder (SPG). Stir occasionally and cook until the vegetables soften and begin to caramelize, usually about 10 minutes. They should be tender-crisp with a hint of sweetness.

5. Step 5: Grill Sausages to Temperature. Continue grilling the sausages, turning them frequently to achieve an even char and prevent burning. Use a reliable meat thermometer to monitor their internal temperature. Cook them until they reach a safe internal temperature of 160°F. This typically takes about 10-15 minutes, depending on the thickness of your sausages and grill temperature.

6. Step 6: Toast the Buns. For an extra touch, lightly grill your hot dog or sausage buns for about 30 seconds per side. This adds a lovely texture and warmth, preventing them from becoming soggy under the juicy toppings. Watch them closely to avoid burning.

7. Step 7: Assemble and Serve. Once the sausages are cooked and the vegetables are tender, it’s time to assemble your masterpiece. Place a grilled sausage onto a toasted bun, then generously top with the caramelized onions and peppers. You can also serve the sausages and vegetables on a plate as a main course, accompanied by your favorite side dishes, skipping the bun entirely for a gluten-free option.

It varies significantly by type and brand. Most traditional pork sausages, especially Italian sausage varieties, are sold raw and require thorough cooking to an internal temperature of 160°F before consumption. In contrast, many chicken and turkey sausages are often pre-cooked and only need to be heated through. Always check the packaging label or consult your butcher to confirm whether the specific sausages you’ve purchased are cooked or uncooked.

For uncooked pork sausages, the minimum safe internal temperature is 160°F (71°C). Unlike some other cuts of pork, ground pork in sausages must reach this temperature to be safe. Don’t worry if they exceed this a bit; sausages are quite forgiving and can handle higher temperatures, up to around 185°F (85°C), without significantly compromising their texture or juiciness.

Generally, uncooked sausages will take about 15-20 minutes to cook through on a grill set to 350-400°F, reaching an internal temperature of at least 160°F. However, cooking time can vary based on several factors, including the thickness and type of the sausages, your grill’s actual temperature, and whether you’re using direct or indirect heat. Always rely on a meat thermometer for accuracy rather than just time.

When grilling sausages, you’ll be actively turning and rolling them to ensure even cooking and to prevent any single spot from burning. Therefore, leaving the grill lid open is perfectly acceptable and often preferred for easy access and monitoring. You can close the lid periodically to help cook them faster and introduce a bit more smoky flavor, but always keep a close eye on them. If you see excessive smoke when the lid is closed, it might indicate flare-ups, meaning your grill temperature is too high or fat is dripping excessively.

Absolutely! To streamline your grilling process, you can slice the onions and bell peppers several hours, or even a day, in advance. Store them in an airtight container in the refrigerator until you’re ready to grill. This simple prep step can significantly cut down on your cooking day efforts.

Olive oil is an excellent choice for sautéing vegetables on the grill. It has a relatively high smoke point suitable for medium-high heat and adds a pleasant flavor. Other good options include avocado oil or grapeseed oil, both of which also have high smoke points and neutral flavors that won’t compete with your dish.

Grilled Sausage and Peppers

• ▢ 6 each Italian sausages (choose hot, sweet, or a mix)
• ▢ 1 large onion (e.g., sweet Vidalia or yellow onion)
• ▢ 3 bell peppers (use a variety of colors like red, yellow, orange)
• ▢ 2 teaspoon olive oil
• ▢ 1 teaspoon salt
• ▢ 1 teaspoon garlic powder
• ▢ ½ teaspoon black pepper
• ▢ 6 buns (hot dog or sausage, or your preferred roll)

• Prepare the Grill: Preheat your outdoor grill to a medium-high temperature, aiming for 350-400°F (175-200°C). Place your cast iron pan or skillet directly onto the grill grates and allow it to heat up as the grill preheats.
• Prep the Vegetables: While the grill heats, wash and slice your onions and bell peppers into uniform, long strips. Ensure they are not too thin, which could cause them to fall through the grates or overcook quickly.
• Grill the Sausages: Place the Italian sausages directly on the preheated grill grates. Using a toothpick or a small, sharp knife, poke about 3-4 small holes in each sausage. This helps render out excess fat and prevents them from bursting while cooking, keeping them juicy.
• Cook the Veggies: Drizzle olive oil into the hot cast iron pan on the grill. Add the sliced onions and bell peppers, then season them with your preferred amount of salt, black pepper, and garlic powder (SPG). Stir occasionally and cook until the vegetables have softened and developed a slight caramelization, typically about 10 minutes.
• Finish Sausages: Continue cooking the sausages, turning them several times with tongs to ensure even cooking and a nice char on all sides. Use an instant-read meat thermometer to check their internal temperature. Cook until they reach a safe internal temperature of 160°F (71°C). This usually takes 10-15 minutes in total, depending on thickness.
• Toast the Buns: If desired, place the hot dog or sausage buns face-down on the grill grates for about 30 seconds to lightly toast them. Remove them immediately to a serving platter to prevent burning.
• Assemble and Serve: Once the sausages are cooked through, remove them from the grill. Place each sausage onto a toasted bun, then generously top with the flavorful grilled onions and peppers. Serve immediately with your favorite condiments, such as mustard, ketchup, relish, or a spicy brown sauce. Enjoy!

• Use a Meat Thermometer: This is non-negotiable for safety and perfection. An instant-read thermometer will ensure your sausages reach 160°F (71°C) without guessing, preventing undercooked meat or dry, overcooked sausages.
• Manage Flare-Ups: Sausages are inherently fatty, which can lead to flare-ups as fat drips onto the hot coals or burners. If flames erupt, quickly move your sausages to an area of indirect heat on the grill or momentarily turn down the heat. This prevents charring while allowing them to cook evenly.
• Clean Your Grates: Always start with a clean grill. After preheating, use a sturdy grill brush to remove any leftover food particles from previous cooks. For an old-school trick, rub a cut-half onion vigorously over the hot grates; its natural juices can help clean and season the surface, and some believe it helps disinfect the grill.
• Don’t Overcrowd the Grill: Give your sausages and the cast iron pan ample space. Overcrowding can lower the grill’s temperature, lead to uneven cooking, and make it harder to manage flare-ups or turn items.