More often than not, I end up with leftovers when I smoke a pork shoulder, and finding ways to use those leftovers is always the most fun part. In this blog post, I’ll cover how I make my delicious bacon and cheese pulled pork sandwich, plus some tips and tricks that make the recipe even better.
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Pulled pork grilled cheese is made by layering smoked pulled pork, cheese, and toppings like bacon or onions between buttered bread, then cooking it on a grill, griddle, or pan until the cheese is melted and the bread is crispy. It’s a quick way to turn leftover pulled pork into a rich, crispy sandwich.
What Is A Pulled Pork Grilled Cheese?
Pulled pork grilled cheese is exactly what it sounds like—a melty grilled cheese sandwich, upgraded with smoked pulled pork. You’re taking leftover barbecue and combining it with that cheesy classic to make something much better. The combination of melted cheese, smoky pork, and a toasted crust makes it one of the easiest ways to repurpose leftovers without it seeming like leftovers. Plus, it’s super easy to customize and make your own, or to make to order if you have guests over.
Ingredient Highlights for the Griddle Sandwich
- Pulled Pork – Use your favorite bbq pulled pork. You can see how I make mine here. This is the backbone of this sandwich.
- BBQ Sauce – I opted for a sweeter sauce this time around, using Blue's Hog's Champions Blend, but I also enjoy a good mustard- or vinegar-based sauce.
- Bacon – I'm of the mindset that bacon makes everything better. Yes, you could stop with the pulled pork, but why stop there? The rendered fat not just adds crunch but additionally enhances the flavor of the entire sandwich.
- Onions – Sautéed onions are something I love to add to a sandwich just about any time I can. The sweetness and umami it adds to the sandwich make it even better.
- Butter + Bacon Grease – Don't just wipe up all of that fat! It makes a great agent to caramelize your sandwich, adding great flavor and an even crispier finish.
Best Cheese for Pulled Pork Grilled Cheese
Really, this comes down to preference. We ALWAYS have white American cheese in our house because it’s both my wife's and my daughter's favorite. It is also a solid choice because it melts quickly and evenly, but it’s not your only option.
But if you’d like a few other options, here are a few options I gravitate towards: Cheddar cheese brings a sharper flavor, pepper jack adds a little heat, and gouda or provolone can give you a smoother, richer bite.
The key is choosing a cheese that melts well and complements the smoky pork instead of overpowering it.
Best Bread for Pulled Pork Grilled Cheese
White bread is the typical choice in our house (Pepperidge Hearty White, to be exact), and it crisps up well on a griddle. You can also use sourdough if you’re feeling elegant, or Texas toast for a thicker sandwich. The goal is something sturdy enough to hold the filling without falling apart when pressed.
How to Make the Sandwich
Step 1: Cook the Bacon
Heat a griddle or cast-iron pan over medium heat and cook the bacon until crispy. Just make sure the temperature is not set too high; bacon cooks best when it can render slowly. Set it aside, but don’t toss the grease—you’ll need it for the onions and the bread.
Step 2: Sauté the Onions
Slice your onions and toss them onto the griddle in that leftover bacon grease (you can add a little butter here if needed). Cook them down until they start to caramelize and become soft, about 5–7 minutes. We're not going for all-out caramelization, as that would take the better part of an hour (but feel free to continue cooking these over low heat if you have the time!).
Step 3: Prep the Bread
In a small bowl, mix your reserved bacon grease with softened butter. Spread the mixture on one side of each slice of white bread—this will help you achieve a crispy, flavorful crust.
Step 4: Build the Sandwich
Place the buttered side of one bread slice down on the griddle (making sure you've reduced the heat to medium-low). Layer with American cheese, bacon strips, a generous pile of pulled pork, a drizzle of BBQ sauce, and a spoonful of sautéed onions. Top with the second slice of bread, buttered side up.
How to Keep Pulled Pork Moist in a Grilled Cheese
Pulled pork can dry out quickly on the griddle if you’re not careful. The easiest way to avoid that is to warm it with a little BBQ sauce or a splash of broth before adding it to the sandwich. That keeps the meat tender and helps it blend better with the melted cheese.
Step 5: Grill and Press
Let it cook until the bottom is golden brown, then carefully flip it over. Press the sandwich slightly with a spatula to get good, even griddle contact. Cook until both sides are crisp and the cheese is melted through.
Note: If your griddle tends to run hot or the bread browns faster than you'd like, reduce the heat to low, or better yet, move it to indirect heat if this option is available in your cooking space.
Step 6: Serve
Once the sandwich is done cooking, remove it from the griddle, slice it in half, and serve.
Interested in More Ways to Use Leftover Pulled Pork? Here are a few of My Favorites!
Recipe
Cheesy Pulled Pork Sandwiches with Sautéed Onions and Bacon
Equipment
- Prep Bowls & Measuring Spoons
- Spatula
- Griddle or Stovetop (with pan if doing this method)
Ingredients
- 8 slices of thick-cut white bread
- 8 strips of bacon
- 1 ½ cups leftover pulled pork room temperature or gently reheated
- 1 cup shredded or sliced American cheese or any meltable cheese
- 1 large yellow onion thinly sliced
- 2 tablespoon softened butter
- 2 –3 tablespoon reserved bacon grease
- Your favorite BBQ sauce for drizzling
Instructions
- Heat a griddle or cast-iron skillet over medium heat. Lay the bacon strips flat and cook until crisp, letting the fat slowly render out—don’t rush this over high heat. Once done, transfer the bacon to a paper towel-lined plate. Reserve the bacon grease in the pan for the next steps.
- Add sliced onions directly into the pan with the hot bacon grease. Sauté over medium heat, stirring occasionally, until the onions soften and begin to caramelize—about 5 to 7 minutes. If the pan looks dry, add a touch of butter to help them along. You’re not going full caramelization here, just a quick cook to bring out that sweet, savory flavor.
- In a small bowl, mix your softened butter with 1–2 tablespoons of the reserved bacon grease. Spread this mixture on one side of each slice of bread. This is your secret weapon for a crispy, flavorful golden crust.
- Turn the heat to medium-low. Lay one slice of bread, buttered side down, onto the griddle. Layer with cheese, bacon, pulled pork, a light drizzle of BBQ sauce, and a spoonful of sautéed onions. Top with the second slice of bread, buttered side facing up.
- Cook the sandwich until the bottom is golden brown and crispy, about 3–5 minutes. Carefully flip it, press lightly with a spatula, and cook the other side until crisp and the cheese is fully melted. If the bread starts to brown too quickly, reduce the heat to low or move it to indirect heat on your grill setup.
- Once the sandwich is crisped to perfection and the cheese is melted , remove it from heat, slice diagonally, and serve hot. Add extra BBQ sauce or slaw on the side if you're feeling fancy.
Notes
- Use room temperature pulled pork for best results. Cold pork can make it harder for the sandwich to heat through evenly without burning the bread.
- Cook bacon low and slow to render the fat correctly — this doubles as a flavorful cooking fat for your onions and bread.
- Don’t skip the butter and bacon grease blend. It gives the bread an unbeatable crust and extra depth of flavor.
- Keep your heat moderate. Griddling at medium-low heat allows everything to melt and crisp at the same time without rushing the process or burning the bread.
- Make-ahead tip: You can cook the bacon and onions in advance to save time. Just reheat gently before assembling the sandwiches.
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