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Turn a basic cookout into something fancy with this charred Italian sausage, olive-packed relish, and fresh herby aioli. Toss all this on a warm bun and you're in for a serious flavor party.
The first time I made these, friends were over and hungry—now it’s what they always hope I’ll cook. The smoky sausage with bright, sharp toppings keeps folks reaching for one more.
Vibrant Ingredients
- Italian sausage links (fresh): Grab hot or mild, whatever’s your jam. Try to spot some herbs in the links and a bit of plumpness for the juiciest result
- Brioche hot dog buns: That rich, buttery flavor really ramps things up. If your bakery has fresh ones, snatch them up
- Quality mayo: You want this for your aioli—one that uses real eggs is best for taste and texture
- Basil (fresh leaves): Pick out good bright ones. Skip any with brown or sad spots for the punchiest green
- Zest of a lemon: Packs brightness and helps balance out the richness. Go for organic if you can for extra zing
- Garlic cloves: You want firm, unsprouted heads for a clean, snappy taste
- Castelvetrano olives: These guys are mild and buttery, perfect for the relish
- Giardiniera: Italian-style pickled veggies for a nice crunch and tangy kick. Choose hot or mild to suit your mood
- Capers: Tiny flavor poppers—super briny, so rinse if they’re too salty for you
- Balsamic drizzle: For a sweet, glossy finish. Look for something thick that hugs a spoon
Simple Step-by-Step
- Get the Rolls Ready:
- Spritz your brioche buns with a bit of cooking spray and toast them, cut-side down, right on the hot grill. Cook till they're golden and crisp, about a minute. This adds flavor and keeps your bread from going soggy later.
- Crank Up the Grill:
- Set up your grill with one hot side and one cooler. Turn only half your burners to high or cram your charcoal all to one side. You'll use the warm side first to cook the sausage gently without burning. Then blast them on the hot part for a seared finish.
- Make the Olive Giardiniera Relish:
- Don’t even bother rinsing out your food processor—throw in olives, giardiniera, and capers. Pulse just a few times so it’s chunky, not mush. The combo is bold, tart, and spicy enough to punch through the sausage’s richness.
- Whip Up Lemon Basil Aioli:
- Add mayo, basil, lemon zest, garlic, salt, and pepper to your food processor. Blitz until it’s totally smooth and bright green. It’s got that zippy lemon and herby flavor that’ll totally wake up whatever you slather it on.
- Start Grilling Soon:
- Lay the sausages over the cooler zone, not straight over fire. Close the lid and let them go for 4–5 minutes. Flip and give them another few minutes so they cook to about 150°F. This keeps them juicy and avoids splitting.
- Hit Them with Direct Flames:
- Scoot the sausages directly onto the flames. Grill each side 2–3 minutes until charred and the middle hits 160°F. This is where you get all that deep smoky goodness and crispy snap.
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The Castelvetrano olives honestly steal the show here. I found them years ago, got obsessed, and now they’re always in my kitchen. Even my picky nephew who “hates anything green” ate two and begged me to show him how to make these.
Easy Prep Ahead
You can easily toss the aioli and relish together days before you need them. The aioli stays tasty for a week in a tight container, but don’t worry if it turns a little less green as it sits. The relish? Even tastier after a day or two and good for up to two weeks in the fridge. When it’s time to grill, just pile it all together.
Top Matches
These sausages go great with a handful of arugula tossed in olive oil and lemon—keeps things light. Grab a chilled Pinot Grigio or Vermentino for sipping, or keep it booze-free with sparkling water, blood orange, and a rosemary twig. For dessert: grilled peaches, a little honey, and a cloud of mascarpone. That’s a win.
Swaps That Work
No Castelvetrano? Grab some green Cerignola olives instead, though they’re not quite as soft or buttery. Want dairy-free? Hunt for vegan-friendly brioche rolls. Use vegan mayo for the aioli—it’ll still taste great. Fresh basil low at the store? Use pesto and ditch the garlic. Turkey or chicken sausages also swap in nicely for a lighter meal.
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If you want to impress, these sausages do the trick—little effort, awesome rewards every time!
Frequently Asked Questions
- → What kind of Italian sausage should I pick?
You can use spicy or mild Italian sausages here. If you’ve got a mix of friends and family, go mild for a crowd-pleaser. But if you want more flavor, fresh sausages from a butcher beat anything already packaged.
- → Is it possible to prep the toppings ahead?
You bet! Lemon basil aioli keeps in the fridge for up to a week if you stash it in a sealed container. The castelvetrano giardiniera relish lasts even longer—pop it in the fridge for two weeks and it’s still tasty. That way, you’ve got less to do when it’s time to eat.
- → What’s zone grilling, and why bother with it?
Zone grilling just means setting up your grill so one part’s really hot and another is cooler. You start the sausages over lower heat so they cook through without splitting. Then, move them over the fire to give them that great char. That’s how you get sausages that are juicy inside and crispy outside.
- → Are there any good swaps for brioche buns?
For sure! Brioche is soft and buttery, but you can try ciabatta for a chewier bite, pretzel buns if you want something hearty, or just use classic hot dog buns for a simple option.
- → Any ideas for what to eat with these sausages?
They go great with easy Italian sides like a peppery arugula salad tossed in lemon dressing, roasted potatoes with rosemary, some grilled zucchini or peppers, or a cold herb-packed pasta salad.
- → What if I don’t own a grill?
No worries! Grab a grill pan or cast-iron skillet. Cook the sausages over medium heat until they hit 150°F inside, then crank the heat to brown them up. Toast the buns in your toaster oven or under the broiler for that finishing touch.