There’s something magical about firing up the smoker on a lazy weekend afternoon. The scent of hickory wood drifting through the backyard, the anticipation of that first bite—it’s what summer memories are made of. I stumbled upon this recipe during a backyard cookout last year when I decided to experiment with stuffing my burgers instead of just topping them. The result? Pure burger perfection that had my friends asking for the recipe before they’d even finished eating.
These Smoked Cheddar Jalapeño Burgers aren’t your average cookout fare. They’re juicy, smoky, and packed with bold flavors that’ll make your taste buds dance. The combination of melted sharp cheddar tucked inside the patty, fiery jalapeños, and that incredible bacon-studded sauce creates layers of flavor that build with every bite.
Total Time: 50 minutes
Yield: 4 servings
Why You’ll Love This Recipe
First off, smoking burgers instead of grilling them takes the flavor to a whole new level. The hickory smoke penetrates deep into the meat, creating a rich, complex taste that you simply can’t achieve on a regular grill. Unlike traditional burgers that can dry out, the 80/20 ground chuck ratio ensures these patties stay juicy and tender throughout the smoking process.
The real genius here is stuffing the cheddar directly into the burger. As it cooks, the cheese melts into pockets of gooey goodness throughout the patty. Add to that the kick from fresh jalapeños, and you’ve got a burger with built-in excitement in every bite.
What Makes These Burgers Special
The bacon burger sauce is a game-changer. Instead of settling for plain mayo or ketchup, this creamy, savory sauce combines the best condiments with actual minced bacon pieces. Tony’s Creole seasoning adds a Louisiana-style kick that ties all the flavors together beautifully.
Plus, these burgers look incredibly impressive but are surprisingly straightforward to make. Whether you’re hosting a crowd or treating your family to something special, this recipe delivers restaurant-quality results with minimal fuss.
Ingredients
For the Burgers
- 2 lbs ground chuck (80/20)
- 8 oz sharp cheddar cheese, cut into ¼” cubes
- 1½ fresh jalapeños, seeded and finely diced
- All-purpose BBQ rub, to taste
- Hickory wood chunks for smoking
- 4 slices pepper jack cheese
- 4 brioche buns, toasted
For the Bacon Burger Sauce
- ½ cup mayonnaise
- 2 tbsp ketchup
- 2 tbsp yellow mustard
- 1 tbsp Worcestershire sauce
- 1 tbsp sweet relish
- ½ lb thick-cut bacon, cooked crispy and minced
- 1 tbsp Tony’s Creole seasoning
- Salt and pepper, to taste
Step-by-Step Instructions
Preparing Your Smoker
Start by preheating your smoker to 225-250°F. Add hickory wood chunks to your coals or wood box—hickory provides that classic smoky flavor that pairs beautifully with beef and cheese. While the smoker comes to temperature, you’ll have plenty of time to prep your burgers and sauce.
Making the Perfect Patty
In a large mixing bowl, combine the ground chuck with the cubed sharp cheddar and diced jalapeños. Sprinkle your BBQ rub over the mixture—don’t be shy here; you want enough seasoning to flavor every bite. Gently mix everything together with your hands until just combined. Overmixing will create tough burgers, so stop as soon as the ingredients are evenly distributed.
Divide the mixture into four equal portions. Form each portion into a patty about ¾ to 1 inch thick, making a slight indentation in the center with your thumb. This prevents the burgers from puffing up into meatballs during cooking. The cheddar cubes should be distributed throughout each patty.
Smoking the Burgers
Place your patties directly on the smoker grates once the temperature stabilizes. Close the lid and let the magic happen. Smoke the burgers for approximately 25-30 minutes, depending on your preferred doneness. For medium burgers, you’re looking for an internal temperature of 145°F.
During the last 3-4 minutes of cooking, lay a slice of pepper jack cheese on top of each patty. Close the lid to let the cheese melt into a gooey blanket of deliciousness. The combination of the sharp cheddar inside and pepper jack on top creates an incredible cheese experience.
Creating the Bacon Burger Sauce
While your burgers smoke, whip up the sauce. In a medium bowl, combine the mayonnaise, ketchup, yellow mustard, Worcestershire sauce, and sweet relish. Stir until smooth and well-blended.
Fold in the minced crispy bacon and Tony’s Creole seasoning. Season with salt and pepper to taste, keeping in mind that the bacon and Creole seasoning already bring some saltiness. Mix thoroughly and set aside. The sauce will thicken slightly as it sits, allowing the flavors to meld together.
Toasting the Buns
About five minutes before your burgers finish smoking, brush the cut sides of your brioche buns with a little butter if desired. Place them cut-side down on the smoker grates or on a clean section of your grill. Toast for 2-3 minutes until golden brown with slight char marks. Brioche buns are sturdy enough to hold up to all these juicy ingredients without falling apart.
Assembly Time
Remove the burgers from the smoker and let them rest for just a minute or two. Spread a generous amount of the bacon burger sauce on both the top and bottom of each toasted bun. Place a smoked patty on the bottom bun, letting that melted pepper jack cheese cascade down the sides.
Serving Suggestions
These burgers are substantial enough to be the star of the meal, but they pair wonderfully with classic sides. Consider serving them alongside crispy sweet potato fries, coleslaw with a tangy vinegar dressing, or grilled corn on the cob brushed with herb butter.
For a complete smoker meal, throw some whole jalapeños on the grates while the burgers cook—they make an excellent spicy garnish. Smoked baked beans or mac and cheese also complement the rich, smoky flavors beautifully.
Don’t forget the beverages! These bold burgers call for ice-cold beer, fresh lemonade, or sweet iced tea. The acidity helps cut through the richness of the cheese and bacon sauce.
Recipe Variations
Spice Level Adjustments
The recipe as written delivers a medium heat level. If you’re sensitive to spice, reduce the jalapeños to just one pepper or remove the seeds and membranes completely—that’s where most of the heat lives. Conversely, if you’re a heat seeker, keep some seeds in the jalapeños or add a few dashes of hot sauce to the burger mixture.
You could also swap the pepper jack cheese topping for habanero jack if you want even more fire. Another option is mixing some cayenne pepper into your BBQ rub for an extra kick throughout the meat.
Cheese Variations
While sharp cheddar and pepper jack create an amazing flavor combination, feel free to experiment. Smoked gouda adds even more smoky depth, while blue cheese creates a bold, tangy profile. Monterey Jack offers a milder, creamier option for those who find pepper jack too spicy.
For an ultra-indulgent version, try using both cream cheese and cheddar in the patty—the cream cheese creates an incredibly creamy texture when melted.
Bacon-Wrapped Option
As mentioned in the notes, wrapping each patty in bacon before smoking takes these burgers to legendary status. Use two strips of bacon per burger, forming an “X” pattern around the patty. The bacon will render as the burger smokes, basting the meat in its own juices while creating a crispy exterior.
This method does add about 10 minutes to the cooking time and increases the richness considerably, so save it for special occasions.
Alternative Cooking Methods
Don’t have a smoker? You can still make delicious versions of these burgers using other methods. On a charcoal or gas grill, use a smoker box filled with soaked hickory chips placed near the heat source. Keep the burgers on the cooler side of the grill and close the lid to trap the smoke.
In a pinch, you can even make these indoors. Pan-sear the patties in a cast-iron skillet over medium-high heat, then finish them in a 350°F oven. While you’ll miss the smoke flavor, you’ll still have incredible cheese-stuffed burgers with amazing sauce.
Make-Ahead Tips
Preparing the Patties
The burger patties can be formed up to 24 hours in advance. Shape them as directed, then place them on a parchment-lined baking sheet with a piece of parchment between each patty to prevent sticking. Cover tightly with plastic wrap and refrigerate until ready to smoke.
This actually benefits the burgers slightly—the flavors have more time to meld together, and the cold patties will hold their shape better when they first hit the smoker.
Bacon Burger Sauce Storage
The bacon burger sauce improves with time as the flavors marry together. Make it up to three days ahead and store it in an airtight container in the refrigerator. Give it a good stir before serving, as some separation may occur. The sauce can also be frozen for up to a month, though the texture may change slightly upon thawing.
Prepping the Jalapeños
Dicing jalapeños can be done a day ahead as well. Store them in a small airtight container in the refrigerator. Similarly, the bacon can be cooked and minced the day before, saving you valuable time on cooking day.
Notes
The spice level of jalapeños can vary significantly from pepper to pepper. Start with 1½ peppers as written, then taste the raw mixture before forming patties (just a tiny pinch). Adjust by adding more jalapeño if needed. Remember that some of the heat will mellow during smoking, so err slightly on the spicier side.
When cubing the cheddar, aim for uniform ¼-inch pieces. Chunks that are too large won’t melt properly, while pieces that are too small will completely melt away. The goal is to have pockets of melted cheese throughout the burger rather than cheese that’s completely dispersed.
Ground chuck with an 80/20 fat ratio is ideal for smoking. Leaner meat will dry out during the longer cooking time, while fattier blends may become greasy. If you can only find 85/15, that will work in a pinch, but watch your burgers carefully to prevent overcooking.
Temperature control is crucial when smoking. Keep your smoker between 225-250°F throughout the cooking process. Much lower and the burgers will take too long and may dry out; much higher and the outside will cook faster than the inside, preventing that beautiful smoke penetration.
FAQ
Can I use pre-shredded cheese instead of cubing my own?
While you technically can, I don’t recommend it. Pre-shredded cheese is coated with anti-caking agents that prevent it from melting smoothly. Block cheese cut into cubes will melt into those gorgeous pockets of gooeyness that make these burgers special. It’s worth the extra minute of knife work.
What if my smoker runs hotter than 250°F?
No problem—just reduce the cooking time. Start checking your burgers around the 20-minute mark with an instant-read thermometer. You’re looking for 145°F for medium burgers. The most important thing is hitting the right internal temperature rather than following the time exactly.
Can I make these burgers spicy without using jalapeños?
Absolutely! Mix some cayenne pepper or your favorite hot sauce directly into the burger mixture. You could also use spicy sausage mixed with the ground chuck (try a 50/50 blend) or add chopped chipotle peppers in adobo for a smoky heat.
Why brioche buns specifically?
Brioche buns have a rich, slightly sweet flavor that complements the smoky, savory burgers beautifully. Their structure is sturdy enough to hold up to juicy burgers and generous sauce without falling apart. That said, any quality hamburger bun will work—pretzel buns are another excellent choice that adds a nice flavor contrast.
Do I need to flip the burgers while smoking?
Typically, no. When smoking at lower temperatures, flipping isn’t necessary and actually releases some of those precious juices. However, if you notice uneven cooking or if your smoker has hot spots, a single flip halfway through won’t hurt.
How do I know when the burgers are done without a thermometer?
While I always recommend using an instant-read thermometer for food safety, you can use the finger test. Press the center of the patty—if it feels like the fleshy part of your palm below your thumb (when making a relaxed fist), it’s roughly medium. Firmer means more well-done, softer means more rare. Clear juices also indicate doneness, though this method is less reliable with these burgers since the cheese can create moisture.
Can I freeze these burgers?
Yes! Freeze the uncooked patties individually wrapped in plastic wrap, then placed in a freezer bag. They’ll keep for up to three months. Thaw completely in the refrigerator before smoking. Don’t freeze cooked burgers, as the cheese and texture won’t hold up as well upon reheating.
Prep Time: 20 minutes
Cook Time: 30 minutes
Category: Main Course
Method: Smoking
Cuisine: American
Nutrition (per serving):
- Serving Size: 1 burger
- Calories: 850
- Protein: 52g
- Fat: 58g
- Carbohydrates: 32g
Note: The original nutrition information appears incomplete. The values above are estimates for the complete burger with bun and sauce.