Grilled Nashville Hot Chicken Sandwich
This grilled Nashville hot chicken sandwich brings the bold, spicy heat of the classic fried version—without the deep fryer. Juicy chicken thighs are marinated in spiced buttermilk, grilled to perfection, then brushed with a fiery cayenne-infused oil. Serve it on toasted buns with pickles, creamy slaw, or a swipe of sauce for a sandwich that’s smoky, spicy, and seriously crave-worthy.
Equipment
- grill
- Grill tongs
- Meat Thermometer
- Small Saucepan
- Basting brush or spoon
- Mixing bowls & measuring spoons
Ingredients
Ingredients for The Chicken
- 2-3 lbs. chicken thighs boneless & skinless
- ¼ C hot sauce + ¼ C pickle juice mixed
- ¼ C paprika
- 2 T cayenne pepper
- 2 T brown sugar
- 2 teaspoon black pepper
- 2 teaspoon salt
- 2 teaspoon garlic powder
- 2 teaspoon onion powder
- 1 teaspoon ground mustard
- 1 teaspoon chili powder
- 1 teaspoon red chili flakes
Ingredients for The Marinade:
- 2 cups buttermilk
- ¼ cup hot sauce
- 1 teaspoon garlic powder
- 1 teaspoon onion powder
- 1 teaspoon smoked paprika
- 1½ teaspoon kosher salt
- 1 teaspoon black pepper
Ingredients for the Nasville Hot Sauce
- 4-5 T butter unsalted
- 4 oz. canola oil
- 1 C hot sauce
- 1 ½ T red pepper
- 1 T paprika
- 1 T brown sugar
- ½ teaspoon garlic powder
- ½ teaspoon salt
Ingredients to Finish
- Hamburger buns toasted, as needed
- 1 C prepared coleslaw
- dill pickles as needed
Instructions
Instructions for the Marinade:
- In a large bowl or zip-top bag, whisk together the buttermilk, hot sauce, garlic powder, onion powder, smoked paprika, salt, and black pepper until well combined.
- Add the chicken thighs, making sure they are fully submerged in the marinade.
- Cover and refrigerate for at least 2 hours or overnight for best results.
- When ready to cook, remove the chicken from the marinade and let the excess drip off. Proceed with seasoning and grilling as directed in the main recipe.
For the Nashville Hot Sauce:
- Place a saucepan over medium-high heat and add the butter. Once the butter has melted, add the oil and all remaining ingredients, stirring as needed. Once the mixture begins to simmer, reduce the heat to low and continue cooking until the sauce is well combined, about 10 minutes.
For the Chicken:
- Preheat the grill to 400 degrees. Meanwhile, pat the chicken thighs dry and trim off any excess fat. Brush the chicken thighs with the pickle juice + hot sauce mix. Then, combine the paprika and the next nine seasonings. Coat the chicken with the prepared rub until covered on all sides. Repeat this step until all thighs have been seasoned.
- Once the grill has preheated, add the chicken and cook, flipping every four to five minutes. Once the chicken registers ~150 degrees, begin liberally applying the sauce using a pastry brush or mop until all the thighs are thoroughly coated. Continue to cook until the internal temperature registers ~180 degrees and the sauce has tacked on. Once this occurs, set the chicken thighs aside and shut off the grill.
To Finish:
- Place a dallop of prepared coleslaw on a hamburger bun followed by the grilled chicken thigh. Top it off with three to four pickles and add the top of the bun. Repeat this process as needed, then serve & enjoy!
Notes
- Marinate Ahead: For maximum flavor and tenderness, marinate the chicken overnight.
- Grill Tip: Use a two-zone setup if flare-ups occur—sear on direct heat, finish on the cooler side.
- Serving Ideas: Great as full sandwiches or sliders for parties. Leftovers also work well in wraps or salads.
- Make It Dairy-Free: Swap the buttermilk with plant milk + vinegar (1 cup milk + 1 tablespoon vinegar) for a similar tenderizing effect.