Wicked Crispy Chicken Sandwich on the Grill Recipe

Last Updated:
September 1, 2024
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If you like “fastfood” chicken sandwiches, these are like those but better.

The technique used here allows for wicked crispy skin and moist, tender meat.

crispy chicken sandwich on grill

Buy Bone-in, Skin on Thighs

Take thighs out of packaging and pat dry.

Don’t do any trimming – the skin will shrink and the bones are going to be pulled out later (easily).

Dry Brining the Thighs a Day or 2 Ahead

Take some kosher salt (1/2 tbsp per thigh, ish) and apply to the meat and skin side of the thighs.

Allow these to dry brine in your refrigerator (skin side up) on the bottom shelf for 2 hours, ideally overnight or a max of 2 days.

This is after 2 days:

chicken thighs dry brine for 2 days

The Next Day, Get Your Grill to 300-325F for Direct Heat BBQ

The idea here is to elevate the meat above the hot coals so that it doesn’t burn.

Any grill can work but I used my charcoal grill with an elevated grill grate.

Place chicken thighs skin side down for 1 hour.

chicken thighs skin side down for 1 hour

After 1 Hour, Flip the Chicken Thighs

When you flip, take some spray cooking oil – like avocado oil, olive oil, duck fat, beef fat, etc. – and spray the skin with the oil.

chicken thighs skin side up

Allow the thighs to continue to grill skin side up for 30 minutes.

Take Off the Grill When ALL Chicken thighs are 200F+ Internal and Rest for 5-10 Minutes

Going this high ensures the meat is fall-off-the-bone tender and that all the skin fat has rendered.

chicken thighs resting for 10 minutes

If any of the skin has “charred” you can use some scissors to snip it off OR leave it on.

Don’t worry about drying the meat out – chicken thighs aren’t white meat and are filled with collagen.

Meaning they’ll taste better when cooked to this high of a temperature.

Once Cooled, Pull the Bone Out of the Meat

The bone should pull easily and cleanly out of the thigh.

pull the bone out of the thigh

Make Spicy Mayo Sauce

In a bowl combine:

  • 2 tbsp Mayo
  • 1 tsp Sriracha or favorite hot sauce
  • 1 tsp Water

In the past I’ve also tried taking like 1/4 cup of hot sauce and putting it into a Ziplock baggy with the thigh and then shaking it.

I find this tends to soften the skin though and prefer the above spread onto the roll instead.

Assemble Chicken Sandwich

To a bun spread the spicy mayo you just made on the top and bottom bun.

Then add your de-boned chicken thigh.

Top with whatever you’d like – dill pickles, onions, lettuce, etc.

Enjoy!

Spicy Grilled BBQ Chicken Sandwich

Crispy skin with spicy mayo
Prep Time5 minutes
Active Time1 hour 30 minutes
Dry Brine16 hours
Total Time17 hours 35 minutes
Course: Main Course

Ingredients

  • 3 Buns
  • 3 whole Bone-in, Skin-on Chicken Thighs
  • 1.5 tbsp Diamond Crystal Kosher Salt

Spicy Mayo

  • 2 tbsp Mayo
  • 1 tsp Sriracha
  • 1 tsp Water

Toppings?

  • Sweet onion
  • Dill pickle chips

Instructions

A Day in Advance, Dry Brine the Thighs

  • Take chicken thighs out of packaging and pat dry.
  • Take 1/2 tbsp of diamond crystal kosher salt and apply to the skin side and meat side of each chicken thigh.
  • Put the salted thighs into your refrigerator, skin-side up and allow these to dry brine for at least 2 hours – ideally overnight OR a max of 2 days.

The Next Day, Get Your Grill to 300-325F

  • The idea here is to elevate the meat above the hot coals so that it doesn’t burn.
    Any grill can work but I used my charcoal grill with an elevated grill grate.
  • Put chicken thighs skin side down for 1 hour.

After 1 Hour, Flip the Thighs

  • When you flip, spray the skin with some cooking oil – like avocado oil, olive oil, duck fat, beef fat, etc.
  • Allow the thighs to grill skin side up for 30 minutes.

Take the Thighs Off the Grill When ALL of them are 200F+ Internal

  • Then rest for 5-10 minutes.
  • Once cooled, take the bone out of the thigh – if you went to 200F, it will easily come out.

Make Sriracha Mayo

  • In a bowl combine the following ingredients.
    2 tbsp Mayo, 1 tsp Sriracha, 1 tsp Water

Assemble Sandwich

  • Grab your buns and smear your sriracha mayo on.
  • Then add your crispy chicken thighs.
  • Top with dill pickles, onions, lettuce, etc. Whatever you like.
    Enjoy!
dylan bio profile picture
Dylan Clay
Dylan Clay is a pitmaster based in New Hampshire, with over 17 years of experience in grilling, smoking, and dehydrating meat. Throughout this time, he has worked with nearly every cut of meat. In 2019, he launched the Barbecue FAQ website to share his extensive knowledge about all things meat, aiming to assist others in making better barbecue at home.

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