Dinner

The Ultimate Smoked Bologna Cheeseburger (Elvis Favorite)

This isn’t just any cheeseburger – it’s the kind of towering, smoky masterpiece that makes grown adults weak in the knees and neighbors suddenly become very friendly when they catch a whiff of what you’re cooking.

Picture this: thick slabs of house-smoked bologna layered with perfectly grilled beef patties, all drowning in melted cheese and stacked so high you’ll need an engineering degree just to figure out how to take a bite.

The magic happens when that bologna chub transforms in your smoker from ordinary deli meat into something that tastes like barbecue heaven decided to crash a burger party.

We’re talking about a 4-5 hour smoking session that fills your backyard with the kind of aroma that stops traffic and makes your phone buzz with texts from curious neighbors.

This recipe creates the ultimate comfort food mashup – smoky, cheesy, indulgent, and completely unapologetic about being extra in all the best ways.

Fair warning: once you make this beast, regular cheeseburgers are going to seem sadly inadequate, and you’ll find yourself planning your next smoking session before you’ve even finished eating.

Ingredients

For the Smoked Bologna

3-4 lb bologna chub (the foundation of greatness)
Yellow mustard (for binding the rub) (for binding the rub)
¼ – ½ cup BBQ rub (homemade recipe below)

For the Burgers

1 .5 lbs 80/20 ground beef (perfect fat ratio for juicy patties)
4 thick cheese slices (for the patties)
2 cups shredded cheese (for the bologna slices)
Salt and black pepper (for seasoning patties) (for seasoning patties)

For Assembly

Quality burger buns (toasted) (toasted)
Lettuce, tomato, onion (fresh toppings) (fresh toppings)
Mayo and mustard (your preferences) (your preferences)

Homemade BBQ Rub

2 Tbsp Lawry’s seasoned salt
2 tsp black pepper
2 tsp paprika
2 tsp granulated garlic
1 tsp granulated onion
1 tsp chili powder

Instructions

Prepare and Smoke the Bologna

1 Preheat your smoker to 250°F (121°C) and ensure you have enough wood chips for a 4-5 hour smoking session. Remove the paper casing from the bologna chub carefully, using a sharp knife to avoid tearing the meat surface.
2 Score the outside of the bologna chub with a thin, sharp knife in a crosshatch pattern about ¼ inch deep. This creates additional surface area for smoke penetration and allows the rub to adhere better during the long cooking process.
3 Apply a liberal coating of yellow mustard to the entire surface using a silicone brush or your hands. The mustard acts as a binder for the rub and adds a subtle tangy flavor that complements the smoke.
4 Generously apply your BBQ rub to all surfaces, pressing it into the scored cuts. Smoke the bologna chub at 250°F (121°C) for 4-5 hours until the internal temperature reaches 165°F (74°C) using an instant-read thermometer.

Rest and Prepare for Grilling

5 Remove the smoked bologna from the smoker and let it cool on the counter for 30 minutes. For enhanced flavor development, wrap in plastic wrap and refrigerate for 2-3 days – this resting period allows the smoke flavor to penetrate deeper into the meat.
6 Preheat your grill for direct high heat cooking to approximately 400-450°F (204-232°C). Using a sharp meat slicing knife or deli slicer, cut the bologna into ⅛-inch thick slices. Plan for 3-4 slices per person and keep them covered until ready to grill.

Grill the Burgers

7 Form 2-4 burger patties at ⅓ pound each from the ground beef. Create a slight indentation in the center of each patty to prevent puffing during cooking. Season both sides generously with salt and black pepper.
8 Once your grill reaches high heat, place the burger patties on the grates and cook for 3-4 minutes per side, flipping only once. After the first flip, place one thick slice of cheese on each burger and close the grill lid to create an oven effect.
9 Continue cooking for another 3-4 minutes until the internal temperature reaches 135-140°F (57-60°C) for medium doneness. Remove the cheeseburgers and let them rest while preparing the bologna slices.

Grill the Bologna and Assemble

10 Place each bologna slice directly on the grill grates and cook for approximately 1 minute per side, flipping once. The edges should start to crisp and develop grill marks.
11 After flipping the bologna slices, sprinkle about 2 tablespoons of shredded cheese on each slice. Remove from the grill after another 1 minute when the cheese begins to melt and bubble.
12 Assemble your masterpiece using toasted buns: spread mayo on both bun halves, add lettuce to the bottom bun, stack 2 cheeseburger patties, layer 3-4 cheesy bologna slices, and top with your favorite burger toppings before crowning with the top bun.

Recommended Equipment and Kitchen Tools

Essential Tools (for best results):

Pellet smoker or charcoal smoker – maintains consistent 250°F (121°C) temperature for the long smoking process
Instant-read thermometer – crucial for monitoring both bologna (165°F internal) and burger doneness (135-140°F)
Sharp boning knife – essential for scoring the bologna chub and removing casing without tearing
Cast iron grill grates – provide superior heat retention and beautiful sear marks on both burgers and bologna

Helpful Upgrades:

Deli slicer or meat slicer – creates perfectly uniform ⅛-inch bologna slices for even cooking and professional presentation
Digital kitchen scale – ensures consistent ⅓-pound burger patties and accurate rub measurements
Silicone basting brush – ideal for applying mustard binder evenly across the bologna surface
Grill basket – prevents smaller bologna pieces from falling through grates during the final grilling stage

Nice-to-Have Options:

Wireless meat thermometer – monitors bologna temperature remotely during the 4-5 hour smoking process
Burger press – creates uniform patty thickness and the perfect center indentation to prevent puffing
Aluminum foil pans – useful for resting the smoked bologna and collecting any rendered juices for flavor enhancement

Recipe Variations and Dietary Modifications

Meat Variations:

Turkey bologna → Use a 2-3 lb turkey bologna chub, reduce smoking time to 3-4 hours until internal temperature reaches 165°F (74°C)
Beef bologna → Increase smoking time to 5-6 hours for denser texture, maintain same 250°F (121°C) temperature
Plant-based option → Substitute thick-cut smoked portobello mushrooms or plant-based deli rounds, reduce cooking time to 2-3 hours

Cheese Alternatives:

Dairy-free modification → Use cashew-based cheese slices or nutritional yeast mixed with dairy-free butter for melting
Premium upgrades → Try aged cheddar, smoked gouda, or pepper jack for enhanced flavor complexity
Low-fat option → Use reduced-fat cheese slices or Greek yogurt-based cheese alternatives

Bun Substitutions:

Gluten-free adaptation → Replace with gluten-free burger buns or large portobello mushroom caps
Low-carb version → Use butter lettuce wraps or grilled eggplant rounds as bun replacements
Keto-friendly → Substitute cloud bread made with eggs and cream cheese

Rub Modifications:

Low-sodium version → Replace Lawry’s seasoned salt with garlic powder and onion powder, add smoked paprika for flavor depth
Spicy variation → Add cayenne pepper, chipotle powder, or hot paprika to the existing rub blend
Sweet and smoky → Include brown sugar and coffee grounds for deeper flavor complexity

Nutritional Information and Health Benefits

Key Nutritional Highlights:
This indulgent creation provides approximately 850-950 calories per serving, with the majority coming from high-quality protein sources. The 1.5 lbs ground beef contributes significant protein (approximately 25-30 grams per serving), while the smoked bologna adds another 15-20 grams. The cheese layers provide calcium and additional protein, though they also contribute to the higher saturated fat content.

Health Benefits of Main Ingredients:
The 80/20 ground beef provides complete proteins containing all essential amino acids necessary for muscle maintenance and repair. Paprika in the rub contains capsaicin and vitamin C, offering anti-inflammatory properties and immune system support. Garlic powder provides allicin compounds that support cardiovascular health, while black pepper contains piperine, which enhances nutrient absorption from other ingredients.

Dietary Considerations:
This recipe is naturally gluten-free when served without buns, making it suitable for those with celiac disease or gluten sensitivity. However, it’s high in sodium (approximately 1,200-1,500mg per serving) due to the processed bologna and seasoned salt. The dish is also high in saturated fat from the cheese and meat combination. Allergen warnings include dairy from cheese and potential soy or corn derivatives in processed bologna.

Portion Size Recommendations:
Given the caloric density, consider this a special occasion meal rather than everyday fare. The recipe serves 2-4 people depending on appetite, with each serving providing substantial protein to maintain satiety for 4-6 hours.

Smart Swaps and Ingredient Substitutions

Common Substitutions:

Bologna chub → Thick-cut ham or pork shoulder (adjust smoking time to 6-8 hours for pork shoulder)
Yellow mustard → Dijon mustard or olive oil as rub binder (olive oil creates different flavor profile)
80/20 ground beef → Ground turkey or ground lamb (turkey requires careful monitoring to prevent drying)
Lawry’s seasoned salt → Kosher salt + garlic powder + onion powder in equal parts

Budget-Friendly Swaps:

Premium bologna chub → Standard deli bologna sliced thick (reduces smoking time to 2-3 hours)
Artisanal cheese → American cheese slices or cheddar cheese (melts consistently and costs less)
Specialty BBQ rub → Homemade blend using pantry spices (saves $3-5 per batch)

Pantry Emergency Substitutions:

Paprika → Chili powder or smoked paprika (smoked version enhances the barbecue flavor)
Granulated garlic → Fresh garlic minced (1 clove = ¼ teaspoon granulated)
BBQ rub → Salt, pepper, and any available spices like cumin, oregano, or thyme

Pro Tips for Substitutions:

When using fresh garlic instead of granulated, mix with oil to prevent burning during the long smoking process
Ground turkey substitutions require adding 1-2 tablespoons olive oil to prevent dry patties
Store homemade rub blends in airtight containers for up to 6 months for maximum flavor retention

Make It Diabetes-Friendly

Carb Reduction Strategies:

Eliminate burger buns → Reduces carbs by approximately 25-30 grams per serving
Use lettuce wraps → Large butter lettuce leaves or iceberg lettuce cups provide crunch with minimal carbs (1-2 grams vs 25-30 grams from buns)
Portobello mushroom caps → Grilled caps add 4-5 grams carbs while providing meaty texture and umami flavor

Sugar-Free Rub Modifications:

Replace Lawry’s seasoned salt → Plain kosher salt + individual spices eliminates hidden sugars often found in seasoning blends
Check bologna ingredients → Some brands contain corn syrup or dextrose; choose sugar-free varieties when available
Homemade rub control → Using individual spices ensures zero added sugars in the seasoning blend

Portion & Timing Tips:

Smaller patties → Form ¼-pound patties instead of ⅓-pound to reduce overall caloric load
Protein pairing → The high protein content (40-50 grams per serving) helps stabilize blood sugar when carbs are eliminated
Estimated carbs without bun → Approximately 5-8 grams from vegetables and trace amounts in spices

Blood Sugar Management:

High protein content slows glucose absorption and promotes satiety
Healthy fats from cheese provide sustained energy without blood sugar spikes
Fiber addition → Serve with grilled vegetables or side salad to increase fiber intake

Perfect Pairing Suggestions

Beverage Pairings:
Bold red wines like Cabernet Sauvignon or Malbec complement the smoky, rich flavors of both the bologna and beef. For beer enthusiasts, IPA or porter styles match the intensity of the barbecue rub, while wheat beer provides a lighter contrast. Non-alcoholic options include sweet tea, cola, or root beer for that classic American barbecue experience. Sparkling water with lime cuts through the richness and cleanses the palate between bites.

Side Dish Recommendations:
Crispy sweet potato fries provide a sweet contrast to the savory, smoky flavors while adding beneficial beta-carotene. Coleslaw with a tangy vinegar-based dressing cuts through the rich cheese and meat combination. Grilled corn on the cob with herb butter complements the outdoor cooking theme, while baked beans with molasses enhance the barbecue flavor profile. Pickle spears and onion rings add textural variety and traditional burger accompaniment appeal.

Complete Meal Ideas:
Start with loaded potato skins or jalapeño poppers as appetizers that match the indulgent theme. Follow the burgers with key lime pie or peach cobbler for a Southern-inspired finish. For entertaining, create a build-your-own burger bar with multiple cheese options, caramelized onions, bacon strips, and avocado slices.

Occasion Suggestions:
Perfect for Fourth of July celebrations, tailgating parties, weekend barbecues, and Father’s Day celebrations. The 4-5 hour smoking time makes this ideal for leisurely weekend cooking projects when you can tend the smoker while enjoying outdoor activities.

Pro Tips and Troubleshooting

Professional Smoking Techniques:
Maintain consistent 250°F (121°C) by adjusting air vents gradually – small adjustments prevent temperature swings that can dry out the bologna. Wrap in foil during the last hour if the exterior becomes too dark before reaching 165°F (74°C) internal temperature. Use fruit woods like apple or cherry for milder smoke flavor, or hickory and oak for more intense smokiness that stands up to the bologna’s robust flavor.

Common Mistakes and Solutions:
Overcooking the burgers is the biggest pitfall – use an instant-read thermometer and remove at 135°F (57°C) for perfect medium doneness, as they’ll continue cooking from residual heat. Bologna splitting during smoking indicates scoring too deeply; limit cuts to ¼ inch maximum depth. Cheese burning on bologna slices happens when grill temperature exceeds 450°F (232°C) – reduce heat or move to cooler grill zones.

Storage and Reheating:
Leftover smoked bologna keeps refrigerated for 5-7 days and actually improves in flavor. Reheat gently in a 300°F (149°C) oven for 10-15 minutes to prevent drying. Freeze portions of smoked bologna for up to 3 months – thaw overnight and slice when ready to use. Cooked burger patties reheat best in a covered skillet with a splash of beef broth.

Make-Ahead Strategies:
Smoke bologna 2-3 days ahead for peak flavor development. Pre-form burger patties and refrigerate up to 24 hours before grilling – place parchment paper between patties to prevent sticking. Toast buns and prepare toppings in advance, storing separately until assembly time.

This isn’t just a burger – it’s a commitment to taking comfort food to its absolute, gloriously excessive limits, and your taste buds will thank you for every single smoky, cheesy, indulgent bite.