A Foolproof Method for Juicy, Charred Grilled Sausage
Grilling fresh sausage seems like it should be the simplest thing in the world – and it is, once you have the right method.
The mistake most grillers make is treating sausage like a burger and taking it straight to direct heat. Trouble is, sausage has a delicate casing and the intense flame splits it wide open. From there, things go downhill fast: drippings ooze into the fire, the grill flares up, and suddenly your sausage is somehow dried out, burnt to a crisp, and raw all at once. 😵💫 Not ideal, especially with a crowd to feed!
The good news is the fix is simple: two-zone grilling. You set up one side of the grill for indirect heat and the other for direct, then cook the sausage in two stages: the cool side gently cooks the sausage through to the center, then the hot side finishes it with a quick char.
It’s the kind of easy summer dinner that will quickly earn a spot in your regular rotation – and best of all, the grill does all the work!
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Step-by-step tutorials (like how to light the grill without burning your eyebrows off) & obsessively-tested tips (for juicy, charred results). Designed for meat lovers & vegetarians alike!
Start with Your Favorite Fresh Sausage
The two-zone setup works beautifully for any raw sausage links: bratwurst, Italian sausage (sweet or hot), Polish sausage, chicken sausage, fresh chorizo, lamb merguez, whatever! Pick whatever catches your eye at the butcher counter. That said, two quick notes:
- If you’re craving traditional beer-boiled bratwurst, be sure to check out these Grilled Wisconsin Beer Brats, my German-Wisconsin family’s famous recipe. Soaked in lager with onions, they’re guaranteed to be the juiciest grilled brats of your life!
- For fully cooked or smoked sausages (hot dogs, kielbasa, andouille, smoked sausage, etc.), you can skip the indirect heat entirely. If you want to level it up, try spiral cut-sausage – it’s a simple trick that creates more surface area for crispy edges, plus a ton of nooks and crannies to nestle more toppings into every bite.
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Buy Now → How to Grill Sausage with the Two-Zone Method
To get started, you’ll need to preheat the grill for two-zone grilling. If you’ve never done this before, don’t let the terminology intimidate you – two-zone grilling simply means having different levels of heat in different areas of the grill. It’s really easy to set up:
- For a gas grill: Turn on the burners on one side of the grill (medium-high) and leave the other side off. Close the lid and let it preheat for 5 minutes.
- For a charcoal grill: Light your coals. Once they are ashed over, pile them all on one side of the grill, leaving the other side empty.
If you’d like a little more support, check out my Complete Guide to Two-Zone Grilling for a full walkthrough on lighting the grill, heat targets, lid management, and more.
👩🏻🍳Don’t be alarmed if the sausages look a little pale in Zone 1! Indirect heat kind of works like an oven – the hot air circulates around the grill, gently cooking the sausages through without splitting the casings. They’re not meant to take on much color at this stage…browning happens in Zone 2!
Let the grilled sausage rest for a few minutes so the juices redistribute throughout the meat, then you’re ready to serve!
🌭Don’t forget to toast those buns! If you’re serving your grilled sausage on a bun, be sure to give them a quick toast while the sausage rests. Spritz the inside of your buns with oil spray and place them on the grates over direct heat. They’ll be toasty and golden in less than 1 minute!
Grilling Sausage Topping and Serving Ideas
Toppings are totally optional, but they’re a fun, easy way to turn grilled sausage into a heartier meal – and a great excuse to set up a build-your-own sausage bar if you’re feeding a crowd!
You can’t go wrong with the classics (mustard! sauerkraut! dijonnaise!), but the best toppings depend on the type of sausage you’re using – bratwurst needs something different than fresh chorizo! Check out the Recipe Notes for a few of my go-to pairings.
From there, all you need is an ice-cold drink and your favorite summer sides.
My Brown Sugar Baked Beans are always a hit – smoky-sweet and mostly hands-off while you’re at the grill. Cooling, creamy Hawaiian Mac Salad is also never a bad idea – Mom’s recipe is ready in just 25 minutes. Potato salad, chips, or a crunchy slaw all work too!
I can’t wait for you to try this Grilled Sausage recipe. If you do give it a try, be sure to let me know! Leave a comment with a star rating below. You can also snap a photo and tag @playswellwithbutter on Instagram. We LOVE seeing your PWWB creations! Happy cooking! ♡
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Juicy Grilled Sausage in 15 Minutes (Two-Zone Method)
- Prep Time: 5 Minutes
- Cook Time: 10 Minutes
- Total Time: 15 minutes
- Yield: Serves 2-4 1x
- Category: Main Dishes
- Method: Grilling & Smoking
- Cuisine: American
Description
Juicy all the way through, with a crispy crust and a char that makes the whole neighborhood smell incredible – mastering Perfectly Grilled Sausage is so much easier than you’d think.
My foolproof 2-zone grilling method cooks fresh sausage links gently over indirect heat first, then over direct heat for a snappy, smoke-kissed finish – no split casings and no flare-ups!
This simple recipe works with any raw sausage in a casing, on a gas or charcoal grill, and is ready in 15 minutes or less!
Ingredients
- 1 pound (raw) fresh sausage links of choice (about 4–6 sausages; see Recipe Notes)
- 4–6 split top brioche buns, hot dog buns, or hoagie rolls
- nonstick cooking spray (such as avocado, canola, or grapeseed oil)
- toppings and condiments of choice
Instructions
Method Overview:
Prepare the grill up for two-zone grilling, creating one side of direct high heat and one side of indirect heat. Cook the sausages over indirect heat first to gently cook them through without bursting the casing, then finish over direct heat until nicely charred. Toast the buns as desired, then serve with all your favorite toppings and condiments.
Step-by-Step Instructions:
- Prepare the grill: Set your grill up for Two-Zone Grilling by creating a zone of direct high heat and a second zone of indirect heat. If using a gas grill, preheat with the lid closed for at least 15 minutes. If using charcoal, light the charcoal at least 30 minutes before grilling.
- Cook the sausages with indirect heat: Place the sausages on the indirect heat side of the grill, as close to the direct heat side as possible without sitting directly over the flame. Close the lid and cook 4-5 minutes per side, until the internal temperature registers 150°F. This gentle, even heat helps the sausages cook through without bursting.
- Char the sausages over direct heat: Transfer the sausages to the direct heat side of the grill. Grill 2-3 minutes per side, until nicely charred and the internal temperature reaches 160°F (165°F for chicken sausage). Remove from the grill and let rest for a few minutes.
- Optional: Toast the buns: Lightly spritz the inside of the buns with cooking spray. Grill 30 seconds to 1 minute, keeping a close eye on them to prevent burning.
- Serve: Nestle the grilled sausages in toasted buns and serve with all your favorite toppings: grilled peppers and onions, sauerkraut, mustard, 2-Minute Creamy Dijonnaise, ketchup…you can’t go wrong. Enjoy!
Notes
- Best sausages for grilling: This indirect grilling method works best with fresh, uncooked sausage links. Bratwurst is a classic choice (try my Grilled Wisconsin Beer Brats if you’re craving the traditional beer-boiled version!), but Italian sausage (hot or sweet), Polish sausage, chicken sausage, and even fresh chorizo are all great options. Gentle indirect heat keeps fresh sausages juicy and flavorful without splitting the casing or drying them out. For fully cooked or smoked sausages, kielbasa, or hot dogs, follow my Spiral-Cut Grilled Hot Dogs method instead.
- Cooking times provided work for a standard 1-inch thick sausage. If your sausage is thicker/thinner, adjust cooking time as needed, and always check for final cooking temperatures with an instant-read thermometer.
- Making a build-your-own grilled sausage bar: Grilled sausages are perfect for a summer party. Set up a DIY sausage bar with toasted buns and a variety of toppings so everyone can build their own perfect bite. Toast a mix of brioche, pretzel, or hoagie rolls and set out mustards, relishes, pickles, and hot sauces for easy mixing and matching. Some favorite topping combinations:
- Classic brat: grilled onions, spicy brown mustard, sauerkraut
- Chicago-style: yellow mustard, sport peppers, diced onion, tomato, pickle spear
- Italian-style: grilled peppers and onions, provolone, balsamic glaze
- Tex-Mex: avocado, pico de gallo, pickled jalapeños, chipotle aioli
- BBQ-inspired: grilled pineapple, barbecue sauce, cilantro
- Cajun-inspired: andouille sausage, creamy slaw, spicy mayo
Follow along with Plays Well With Butter on Instagram, YouTube, Facebook, and Pinterest for more unfussy recipes that pack a big punch of flavor!
This recipe worked so well, the 2-zone grilling is a great method
The absolute best secret to foolproof grilling! So happy you enjoyed, Maria!
How hot should the grill be??
High heat, med heat or low heat?
Hi Brian! This recipe calls for two-zone grilling – starting the sausage over low heat, and then finishing it with a char over direct heat. You can find more detailed instructions in the post as well as the recipe card. Hope that helps!
this method works perfectly every time! Jess is a grilling queen and she has totally upped my grill game
☺️You know how to make a gal’s day, Courtney!!! Thanks for the comment!
this works perfectly! thanks for being my grilling guru, Jess!
We are so glad you enjoyed! If you haven’t already be sure to check out our new grilling tips & recipes that have been shared so far this summer here!
Thank you so much for your helpful shearing post!
=) xo