If there’s a dish that belongs at Kentucky Derby season, it’s this Grilled Kentucky Hot Brown on the Big Green Egg. Piled with smoked turkey, crispy pig candy bacon, grilled tomato, and a silky Mornay sauce, this open-faced sandwich is comforting and elevated by the grill’s live-fire flavor.
The original Kentucky Hot Brown is a Louisville classic, and for many families it’s a special tradition. Recreating it on the Big Green Egg adds wood-fired smoke, crisped bread, and a deeper overall flavor that an oven can’t match. It’s ideal for Derby Day, a weekend brunch, or a memorable casual dinner with friends.
Preparing the Turkey
If you don’t have holiday leftovers, boneless turkey breasts work perfectly for a Hot Brown. Keep the seasoning simple—kosher salt and black pepper—since the Mornay sauce and bacon provide most of the flavor. For reliably tender, juicy slices, the turkey can be cooked sous vide at 140°F for 2½ hours after vacuum sealing. This method yields even doneness and prevents drying.
After sous vide, briefly place the turkey on the Big Green Egg to pick up a light smoky note and grill color—about 2 to 3 minutes per side is enough. Let the meat rest, then slice thinly for assembling the sandwich.
Making the Pig Candy Bacon
Great bacon is essential. To make pig candy, set the Big Green Egg for indirect cooking at 300°F. Combine brown sugar, black pepper, and a pinch of cayenne, then coat thick-cut bacon evenly with the mixture. Place the bacon on a rack and cook 30–40 minutes until caramelized and crisp. In the final 5 minutes, brush with maple syrup to add a glossy finish. Let the bacon cool slightly before using—its sweet, smoky crunch is a highlight of the Hot Brown.
Grilling the Tomatoes and Bread
Raise the Egg to about 350°F for direct grilling. Toss tomato wedges with olive oil, kosher salt, and black pepper. Brush thick slices of Italian bread with melted butter and season lightly. Grill the tomatoes a few minutes until slightly softened and charred, and toast the bread until it has good grill marks but remains sturdy enough to hold the toppings. The subtle char on both components adds a welcome layer of flavor.
Making the Mornay Sauce
The creamy Mornay ties the sandwich together. In a saucepan over medium heat, melt 1 tablespoon butter and whisk in 1 tablespoon all-purpose flour to make a smooth roux. Slowly whisk in 1 cup 2% milk, add 1/4 tsp black pepper and a pinch of salt, and simmer about 5 minutes until the sauce thickens enough to coat a spoon. Remove from heat and stir in 1/4 cup freshly grated Parmigiano-Reggiano until fully melted and silky. The sauce should be rich and pourable.
Assembling the Kentucky Hot Brown
To finish, close the Egg’s vents to remove active direct heat and rely on residual warmth. In a cast iron pan, arrange the grilled Italian bread, top with sliced turkey and grilled tomato wedges, and pour the warm Mornay sauce generously over each open-faced sandwich. Return the pan to the Egg for 10–15 minutes until the sauce is bubbling and lightly browned. Finish by topping each portion with the pig candy bacon and serve hot from the pan for a rustic presentation that keeps the dish warm.
Grilled Kentucky Hot Brown on the Big Green Egg
Equipment
- Cast iron pan
Ingredients
Mornay Sauce
- 1 tbsp butter
- 1 tbsp all-purpose flour
- 1 cup 2% milk
- 1/4 tsp black pepper
- 1/8 tsp salt
- 1/4 cup grated Parmigiano-Reggiano
Bacon
- 1 lb thick-cut bacon
- 1/2 cup brown sugar
- 1/2 tsp black pepper
- 1/2 tsp cayenne pepper
- 1/4 cup maple syrup
Sandwich
- 2 lb boneless, skinless turkey breasts
- Salt and black pepper, to taste
- 2 large tomatoes, cut into wedges
- 2 tbsp olive oil
- 4 thick slices Italian bread
- Salt and black pepper for seasoning the bread and tomatoes
Instructions
Mornay Sauce
- Melt butter over medium heat, whisk in flour to form a roux.
- Slowly whisk in milk, season with salt and pepper, and cook until thickened, about 5 minutes.
- Remove from heat and stir in Parmigiano-Reggiano until smooth.
Bacon
- Preheat the Big Green Egg to 300°F for indirect cooking. Mix brown sugar, black pepper, and cayenne. Coat bacon with the mixture.
- Place bacon on a rack and cook 30–40 minutes until crisp and caramelized. Brush with maple syrup during the last 5 minutes.
- Remove and let cool slightly before using.
Turkey
- Season turkey with kosher salt and black pepper. Vacuum seal and cook sous vide at 140°F for 2½ hours.
- Pat turkey dry and preheat the Egg to 350°F for direct cooking.
- Grill turkey briefly to add smoke and grill marks, 2–3 minutes per side. Rest 10 minutes, then slice thin.
Bread & Tomatoes
- Toss tomato wedges with olive oil, salt, and pepper.
- Brush Italian bread with melted butter and season lightly.
- Grill tomatoes and bread on the 350°F grate until tomatoes are lightly charred and bread is toasted with grill marks.
Assembly
- Close the Egg vents to remove active direct heat and use residual heat to finish the sandwiches.
- In a cast iron pan, layer grilled bread, sliced turkey, and tomato wedges. Pour warm Mornay sauce over each open-faced sandwich.
- Return the pan to the Egg for 10–15 minutes until the sauce bubbles and browns slightly. Top with pig candy bacon and serve hot.
Enjoy this elevated Hot Brown hot from the pan—smoky, creamy, and deliciously indulgent.