Grilling sausage over medium heat with frequent turning prevents the casings from bursting while ensuring a juicy interior. If you have ever wondered how to cook sausage on the grill, you are in the right place. This guide covers everything from choosing the right sausage to avoiding common mistakes, so you get perfect results every time.
How To Cook Sausage On The Grill
Grilling sausage is simple, but a few key steps make the difference between dry, burnt links and juicy, flavorful ones. The most important rule is to control your heat and turn the sausages often. Let’s break down the process step by step.
Choose The Right Sausage For Grilling
Not all sausages are created equal for grilling. Fresh sausages like bratwurst, Italian sausage, or chorizo work best because they have a high fat content that keeps them moist. Pre-cooked sausages like hot dogs or kielbasa also grill well, but they need less time.
- Fresh sausages: Raw, require longer cooking time
- Pre-cooked sausages: Already cooked, just need reheating
- Smoked sausages: Fully cooked, heat through quickly
Avoid very lean sausages, as they dry out fast on the grill. Look for sausages with visible fat marbling for the best flavor and texture.
Prepare Your Grill And Sausages
Start by cleaning your grill grates. A clean surface prevents sticking and gives you those nice grill marks. Then, set up your grill for two-zone cooking: one side with direct medium heat, the other with indirect heat.
- Preheat your gas or charcoal grill to medium heat (about 350-400°F).
- Brush the grates with oil to prevent sticking.
- If using charcoal, bank the coals to one side for direct and indirect zones.
- Take sausages out of the fridge 15-20 minutes before grilling to take the chill off.
- Pat sausages dry with paper towels to help browning.
Do not pierce the sausages with a fork! This lets juices escape and dries them out. The casings will naturally burst if you cook them correctly.
The Best Method: Indirect Heat First, Then Direct
This two-step method is foolproof. Start by cooking the sausages over indirect heat to gently bring them up to temperature without burning the outside. Then, finish over direct heat for color and char.
Place the sausages on the indirect heat side of the grill. Cover the grill and cook for 8-10 minutes, turning every 2-3 minutes. This slow cooking ensures the inside reaches a safe temperature while the outside stays intact.
After that, move the sausages to the direct heat side. Grill for 2-3 minutes per side, turning frequently, until the casings are browned and slightly crisp. Total cooking time is usually 12-15 minutes for fresh sausages.
Use A Meat Thermometer For Safety
Guessing doneness by color or feel is risky. The only reliable way to know if your sausage is cooked is with an instant-read thermometer. Insert it into the thickest part of the sausage, avoiding the casing.
- Fresh pork or beef sausage: 160°F internal temperature
- Chicken or turkey sausage: 165°F internal temperature
- Pre-cooked sausage: Just heat to 140°F
If you don’t have a thermometer, look for clear juices when you cut into the sausage. But a thermometer is much more accurate and prevents undercooking or overcooking.
Turn Frequently To Prevent Bursting
Turning sausages every 2-3 minutes is crucial. This distributes the heat evenly and prevents one side from getting too hot, which causes the casing to split. Use tongs, not a fork, to turn them gently.
If a sausage does burst, don’t panic. Just move it to indirect heat to finish cooking. The burst area will seal up, and the flavor will still be good. To avoid this, keep the heat medium, not high.
Add Smoke Flavor With Wood Chips
For extra depth, add soaked wood chips to your charcoal or a smoker box on a gas grill. Apple, hickory, or cherry wood work well with sausages. Place the chips over the heat source before adding the sausages.
The smoke infuses the sausage during the indirect cooking phase. This adds a subtle, smoky flavor that complements the meat and spices. Don’t overdo it—a little smoke goes a long way.
Glaze Or Sauce At The End
If you want to add barbecue sauce, mustard, or a glaze, do it during the last 2-3 minutes of grilling. Sugary sauces burn quickly over direct heat, so apply them only after the sausages are nearly done.
Brush a thin layer on each side and let it caramelize for a minute. This gives you a sticky, flavorful coating without charring. For beer-brined sausages, skip the sauce and let the natural flavors shine.
Rest The Sausages Before Serving
Let the sausages rest for 3-5 minutes after grilling. This allows the juices to redistribute throughout the meat. If you cut into them immediately, the juices will run out onto the plate, leaving dry sausages.
Resting is a small step that makes a big difference. Cover them loosely with foil to keep warm while you finish the rest of your meal.
Common Mistakes To Avoid
Even experienced grillers make mistakes with sausages. Here are the most common ones and how to avoid them:
- Grilling over high heat: Burns the outside, leaves inside raw
- Not turning enough: Causes uneven cooking and burst casings
- Piercing the casing: Lets juices escape, dries out the sausage
- Overcooking: Makes sausages tough and dry
- Grilling cold sausages: Leads to uneven cooking
Avoid these, and you will have great results every time. The key is patience and attention to heat control.
How To Grill Different Types Of Sausage
Different sausages need slight adjustments. Here is a quick guide for popular varieties:
Bratwurst
Grill over medium heat for 12-15 minutes. Brats are often parboiled in beer before grilling to ensure they cook through. If you skip parboiling, use the indirect heat method.
Italian Sausage
Sweet or hot Italian sausages take about 12-14 minutes. They have a high fat content, so they stay juicy. Turn often to prevent flare-ups from dripping fat.
Chicken Or Turkey Sausage
These leaner sausages cook faster, about 8-10 minutes. Watch them closely to avoid drying out. Brushing with oil helps keep them moist.
Kielbasa Or Smoked Sausage
Since they are pre-cooked, just heat them through for 6-8 minutes. You want grill marks and a slight char without overcooking.
Andouille Or Chorizo
These spicy sausages grill well in 10-12 minutes. They have a firm texture and hold up to high heat, but still use medium heat for best results.
Grilling Sausages On A Gas Grill Vs Charcoal
Both work well, but there are differences. Gas grills offer precise temperature control, making it easier to maintain medium heat. Charcoal grills add a smoky flavor that gas cannot replicate.
For gas grills, preheat with the lid closed for 10 minutes. Set the burners to medium. For charcoal, wait until the coals are covered with white ash before cooking. This indicates they are at the right temperature.
If using charcoal, spread the coals evenly for direct heat or bank them to one side for two-zone cooking. The two-zone method is easier to manage with charcoal.
What To Serve With Grilled Sausages
Grilled sausages are versatile and pair well with many sides. Classic options include:
- Buns with mustard, sauerkraut, or grilled onions
- Potato salad or coleslaw
- Grilled peppers and onions
- Baked beans or corn on the cob
- A fresh green salad
You can also slice the sausages and add them to pasta, rice bowls, or tacos for a quick meal.
Storing And Reheating Leftover Grilled Sausages
Leftover sausages keep well in the fridge for 3-4 days. Store them in an airtight container. To reheat, use a skillet over medium heat with a splash of water or broth to add moisture.
You can also reheat them on the grill for a few minutes per side. Avoid microwaving, as it makes the casings rubbery. Sliced sausages reheat well in soups or stir-fries.
Frequently Asked Questions
Can I grill frozen sausages?
Yes, but it takes longer and requires more care. Thaw them in the fridge overnight for best results. If grilling from frozen, use indirect heat and cook for 18-20 minutes, then finish over direct heat.
Why do my sausages burst on the grill?
Bursting happens when the heat is too high or you don’t turn them enough. The casing expands faster than the inside can cook, causing it to split. Use medium heat and turn every 2-3 minutes.
How long do you grill sausages on each side?
For fresh sausages, grill 2-3 minutes per side over direct heat after the indirect cooking phase. Total time is about 12-15 minutes, turning frequently.
Should I boil sausages before grilling?
Boiling is optional but helpful for thick sausages like bratwurst. Parboiling in beer or water for 5-10 minutes ensures they cook through without burning on the grill. It also adds flavor.
What is the best heat for grilling sausages?
Medium heat, around 350-400°F, is ideal. High heat burns the outside and leaves the inside raw. Low heat takes too long and dries them out.
Now you know exactly how to cook sausage on the grill. With the right technique, you will get juicy, perfectly cooked sausages every time. Fire up the grill and enjoy!