This Smoked Grilled Cheese Sandwich takes the classic sandwich to new heights with crispy, buttery bread, a blend of melty cheese, and that signature wood-fired flavor from the pellet grill. This is my new favorite sandwich, and is perfect for game days, lazy weekends, or whenever you're craving next-level comfort food!
If you love this recipe, try my Smoked Brisket Sandwich, Air Fryer Reuben Sandwich, or Venison Philly Cheesesteak Sandwich next!
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Why you'll love this recipe
- Restaurant quality at home! That perfect golden-brown crust and melty cheese center rivals any fancy grilled cheese you'd get at a restaurant.
- Smoky twist on a classic! Your pellet grill adds a kiss of smokey flavor that takes this sandwich from good to incredible. It's like grilled cheese and smoked cheese combined!
- Ready in minutes! From start to finish, you'll have hot, melty grilled cheese in about 10 minutes
- Customizable: Feel free to use different cheese and bread.
Recipe ingredients
All ingredients for this recipe are shown in the pic below and special notes are made in this bulleted list to assist you.
- Bread. My go-to is thick-sliced Sourdough Sandwich Bread, but you can use any kind of bread. Texas toast, rye bread, or homemade - just make sure it's sliced thick enough to handle the heat and melty cheese! Want to make your own? Try my Easy No Knead Sourdough Bread, Sourdough Discard Sandwich Bread, Soft Whole Wheat Bread, or shape Grandma's Old Fashioned Air Buns into a loaf!
- Cheese. I used one slice of sharp cheddar cheese and gouda for each sandwich. The cheddar gives you that classic grilled cheese flavor, while the gouda adds something extra. I recommend smoked gouda if you have it. Just fold each slice to fit inside your bread if needed. You could also use Gruyere or Fontina.
- Butter. Use softened unsalted butter and spread it generously on both sides of each bread slice - about ½ tablespoon per side. This creates that perfect golden-brown crust.
See the recipe card below for full information on ingredients and quantities.
How to make it
Here's how to make this easy smoked grilled cheese with step-by-step photos. (The full recipe is in the recipe card below!)
- Preheat your pellet grill to 425°F. Place a 12-inch cast iron skillet or grill pan directly on the grill grates to heat up while the grill comes to temperature. Note: A hot pan is crucial for achieving that perfect golden crust.
- While the grill heats, butter both sides of four bread slices, using about ½ tablespoon of softened butter per side. Have your cheese slices ready. Note: Room temperature butter spreads easily without tearing the bread.
- When the grill and pan are hot, place two slices of buttered bread in the skillet. Top each with one slice of cheddar and one slice of gouda, folding the cheese if needed to fit within the bread edges. Add the remaining buttered bread on top.
- Close the grill lid and let sandwiches cook undisturbed for 5 minutes until golden brown on the bottom. Note: Resist checking too often - keeping the lid closed maintains steady temperature.
- Using a flipper, carefully flip sandwiches and cook another 5 minutes with the lid closed until the second side is golden and the cheese is fully melted. If needed, reduce temperature to 350°F for 1-2 minutes more to melt cheese completely.
- Transfer to a cutting board, let rest 1 minute, then slice diagonally and serve immediately while the cheese is hot and melty. Enjoy!
Top tips
- Watch your heat. Keep your grill steady at 425°F. Opening the lid only when necessary helps maintain temperature.
- Time it right. Five minutes per side gives you perfectly golden bread and fully melted cheese.
- Stay organized. Have your buttered bread and cheese slices ready before starting. Assembly goes quickly once your pan is hot.
Variations
- The Ultimate Classic. Use two slices of sharp cheddar per sandwich for traditional flavor.
- Three Cheese Deluxe. Add a slice of provolone along with the cheddar and gouda.
- Smoky Southwest. Use Monterey jack cheese or pepper jack instead of gouda and add a thin layer of Pico de Gallo.
- French Onion. Replace both cheeses with gruyere and add caramelized onions.
- Bacon. Add a couple slices of bacon (cooked) to each sandwich.
- Spreads. Add a teaspoon of Dijon mustard or mayonnaise to the inside of one piece of bread before adding cheese for extra flavor - or use both!
Equipment
This sandwich can be made on any type of grill as long as you have a flat cooking surface:
- Pellet Grill. I used my Traeger with a Camp Chef cast iron griddle, but any pellet grill works great - Pit Boss, RecTeq, or Camp Chef - with a cast iron pan.
- Blackstone. While it won't have that smoky flavor, you can still use it to make grilled cheese! Preheat one section to medium-high heat (about 425°F) and follow the same timing.
What to serve with smoked grilled cheese
Here are the perfect pairings for your sandwich:
- Classic Comfort. Nothing beats the combination of grilled cheese with Roasted Tomato Soup. The smoky sandwich and creamy soup are meant for each other.
- Fresh and Light. Balance the richness with Greek Cucumber Salad or Broccoli Crunch Salad.
- Extra Cozy. On chilly days, pair with Air Fryer French Fries or Smoked Baked Beans for the ultimate comfort food experience.
Storage instructions
Keep leftover grilled cheese wrapped in foil at room temperature for up to 2 hours. While best enjoyed fresh off the grill, you can reheat leftovers in a covered skillet over low heat until the cheese melts.
Recipe FAQs
Yes! Whether you have a Traeger, Pit Boss, or any other pellet grill, this recipe works great. Just maintain that 425°F temperature and use a good cast iron skillet.
I like mild woods like apple or cherry for this recipe. Stronger woods like hickory can overpower the cheese flavor.
If your bread is browning before the cheese melts, lower the temperature to 350°F and give it a few more minutes with the lid closed.
More easy smoker recipes you'll love
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Printable Recipe
Smoked Grilled Cheese
Ingredients
- 4 slices bread (thick slices)
- 4 tablespoons butter softened
- 2 slices sharp cheddar cheese
- 2 slices gouda
Instructions
- Preheat your pellet grill to 425°F and place a large cast iron skillet or grill pan directly on the grill grates to heat up.
- While the grill heats, butter both sides of each bread slice generously, using about ½ tablespoon of butter per side.
- When the grill and pan are hot, place two slices of buttered bread in the skillet. On each bread slice, add one slice each of cheddar and gouda, folding if needed to fit inside the bread edges. Top with remaining buttered bread slices.
- Close grill lid and cook for 5 minutes until golden brown on the bottom.
- Carefully flip and cook another 5 minutes with the lid closed until the second side is golden and the cheese is fully melted.
- Transfer to a cutting board and let rest for 1 minute before slicing diagonally. Serve immediately. Enjoy!
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Notes
- A sturdy, crusty bread works best. It holds up to the heat and gives you that perfect golden crust.
- Layer your cheese slices by folding them to fit within the bread edges. This prevents cheese from melting out and burning.
- Assembling directly on the hot cast iron helps the cheese start melting immediately.
- While best enjoyed fresh off the grill, leftovers can be saved for up to 24 hours. Reheat in a covered skillet over low heat until warm.
Nutrition
The provided nutrition information is automatically calculated. Accuracy is not guaranteed.
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