Chili Chicken Sandwiches -- When the Smoker Is Ready, So Are You

Spring cleaning of the grill and smoker. Deep clean, new grates, seasoned the smoker with a long burn. The tools are ready for another season. I made smoked chicken thighs for the building and Mr. Peterson declared them "your best yet." The best yet keeps getting better. That is the point.

After a full day scrubbing grates and running a seasoning burn to get the smoker back in fighting shape, I wanted the first real cook of the season to mean something — something bold, a little heat, and built for sharing. Chili Chicken Sandwiches were exactly that: big flavor, enough to feed the building, and the kind of dish that holds up to a compliment like “your best yet.” When Mr. Peterson says that, you write it down and you make sure the recipe is ready to repeat.

Chili Chicken Sandwiches

Prep Time: 15 min | Cook Time: 25 min | Total Time: 40 min | Servings: 6

Ingredients

6 boneless, skinless chicken thighs
2 tablespoons olive oil
2 teaspoons chili powder
1 teaspoon smoked paprika
1 teaspoon garlic powder
1/2 teaspoon onion powder
1/2 teaspoon ground cumin
1/4 teaspoon cayenne pepper
1 teaspoon kosher salt
1/2 teaspoon black pepper
6 sturdy sandwich rolls or brioche buns
1/2 cup mayonnaise
1 tablespoon hot sauce
1 teaspoon lime juice
1 cup shredded cabbage or coleslaw mix
1 avocado, sliced (optional)
Sliced pickled jalapeños, for serving

Instructions

Make the rub. In a small bowl, combine chili powder, smoked paprika, garlic powder, onion powder, cumin, cayenne, salt, and black pepper. Stir to blend evenly.
Season the chicken. Pat chicken thighs dry with paper towels. Brush both sides with olive oil, then coat thoroughly with the spice rub. Let rest at room temperature for 10 minutes while your grill or smoker comes to temperature.
Cook the chicken. Grill or smoke chicken thighs over medium-high heat (375°F–400°F) for 6–8 minutes per side, or until internal temperature reaches 165°F and the exterior is nicely charred. Let rest 5 minutes before slicing.
Make the chili aioli. Whisk together mayonnaise, hot sauce, and lime juice in a small bowl. Taste and adjust heat to your liking.
Toast the buns. Place rolls cut-side down on the grill or in a cast-iron skillet for 1–2 minutes until lightly golden.
Assemble. Spread chili aioli on both sides of each bun. Layer with sliced chicken, shredded cabbage, avocado if using, and pickled jalapeños. Serve immediately.

Nutrition (per serving)

Chili Chicken Sandwiches -- When the Smoker Is Ready, So Are You