Chopped Italian Sandwich Recipe for the Yoder Smokers YS640s – Ultimate Meat-Lover’s Sub
Chopped Italian Sandwich Recipe for the Yoder Smokers YS640s – Ultimate Meat-Lover’s Sub! is a easy American (Barbecue) with Italian influences recipe that serves 6. 680 calories per serving. Recipe by allthingsbbq on YouTube.
Prep: 10 min | Cook: 6 min | Total: 26 min
Cost: $47.37 total, $7.90 per serving
Ingredients
- 1 lb Salami (sliced, then cut into 1‑inch pieces for grilling)
- 1 lb Pepperoni (sliced, then cut into 1‑inch pieces for grilling)
- 1 lb Ham (thinly sliced, then cut into 1‑inch pieces for grilling)
- 8 oz Provolone Cheese (shredded or cut into small cubes)
- 1 head Romaine Lettuce (use the crunchy inner leaves, roughly chopped)
- 2 Tomato (medium, seeded and diced)
- 0.5 cup Mayonnaise (regular or light)
- 2 tbsp Red Wine Vinegar
- 1 tsp Cattleman's Grill Italiano Seasoning (or any Italian herb blend)
- 1 tbsp Balsamic Glaze (for drizzle)
- 1 tbsp Olive Ranch Dressing (optional, for extra flavor)
- 6 Pepperoncini (sliced for garnish)
- 1 French Bread Loaf (about 12‑inch loaf, crusty exterior)
Instructions
Preheat Pellet Grill
Set the YS‑640S pellet grill to 350°F and let it preheat for about 5 minutes.
Time: PT5M
Temperature: 350°F
Grill the Meats
Place the salami, pepperoni, and ham pieces in a single layer on the grill. Cook for 3 minutes, flip, then cook another 3 minutes until lightly crisp and some fat is rendered.
Time: PT6M
Temperature: 350°F
Cool the Grilled Meats
Transfer the grilled meats to a large mixing bowl and let them rest for 2 minutes while you prep the vegetables.
Time: PT2M
Prep Fresh Vegetables
Roughly chop the romaine lettuce (using only the crunchy inner leaves) and dice the tomatoes. Add them to the bowl with the grilled meats.
Time: PT3M
Add Cheese
Stir in the shredded provolone cheese, distributing it evenly.
Time: PT1M
Make the Dressing
In a small cup, whisk together mayonnaise, red wine vinegar, Italian seasoning, balsamic glaze, and olive ranch dressing.
Time: PT1M
Combine Everything
Pour the dressing over the meat‑cheese‑vegetable mixture. Toss thoroughly until everything is evenly coated.
Time: PT2M
Prepare the Bread
Slice off the top of the French loaf, then hollow out the interior using a small serrated knife, leaving about 1‑inch thick walls to hold the filling.
Time: PT2M
Load the Sandwich
Spoon the chopped mixture into the hollowed loaf, packing it firmly but not crushing the bread. Garnish the top with sliced pepperoncini.
Time: PT2M
Slice and Serve
Using a serrated bread knife, cut the loaded loaf into 6 equal portions. Serve immediately or wrap tightly for later.
Time: PT2M
Nutrition Facts
- Calories
- 680
- Protein
- 30 g
- Carbohydrates
- 55 g
- Fat
- 38 g
- Fiber
- 4 g
Dietary info: Contains pork, Contains gluten, Contains dairy, Not vegetarian, Not vegan
Allergens: Dairy, Eggs, Gluten, Pork
Ingredient Substitutions
- Instead of Salami: Genoa salami, Soppressata
- Instead of Pepperoni: Spicy Italian sausage, Calabrese salami
- Instead of Ham: Smoked turkey, Prosciutto
- Instead of Provolone Cheese: Mozzarella, Swiss cheese
- Instead of Romaine Lettuce: Iceberg lettuce, Butter lettuce
- Instead of Tomato: Cherry tomatoes, Heirloom tomato
- Instead of Mayonnaise: Greek yogurt, Aioli
- Instead of Red Wine Vinegar: Apple cider vinegar, white wine vinegar
- Instead of Cattleman's Grill Italiano Seasoning: Italian seasoning, Herbes de Provence
- Instead of Balsamic Glaze: Reduced balsamic vinegar, Honey
- Instead of Olive Ranch Dressing: Ranch dressing, Italian vinaigrette
- Instead of Pepperoncini: Pickled banana peppers, Pickled jalapeños
- Instead of French Bread Loaf: Italian hoagie roll, Baguette
Equipment Needed
- YS‑640S Pellet Grill
- Grill Tongs
- Chef’s Knife
- Cutting Board
- Large Mixing Bowl
- Wooden Spoon or Spatula
- Bread Knife
- Serving Platter (optional)
Critical Steps — Do Not Skip
- Grilling the meats just enough to get crisp edges without drying them out.
- Ensuring the dressing is well‑mixed and evenly coats the mixture.
- Hollowing the French loaf correctly to hold the filling without collapsing.
Chef Tips from the Video
- Use equal weights of each meat for balanced flavor and texture.
- Choose a crunchy romaine heart for maximum crunch without excess water.
- A light drizzle of balsamic glaze adds a sweet‑tart contrast to the salty meats.
Troubleshooting
Sandwich is too dry.
Add an extra tablespoon of mayonnaise or a drizzle of olive ranch to re‑moisten the filling.
Filling is overly salty.
Increase the amount of fresh lettuce and tomato, or add a splash of extra vinegar to balance the flavor.
Bread collapses under the weight of the filling.
Make sure the loaf walls are at least 1‑inch thick and consider toasting the inside lightly for extra strength.
Storage
Refrigerator: Store leftovers in an airtight container for up to 3 days.
Freezer: Not recommended; the bread will become soggy after thawing.
Room temperature: Do not leave at room temperature for more than 2 hours.
Make-Ahead Tips
- Grill the salami, pepperoni, and ham up to a day ahead; store in the fridge and reheat briefly before mixing.
- Prepare the dressing and keep it refrigerated; combine just before assembling the sandwich.
- The bread can be hollowed and wrapped in plastic wrap a few hours ahead to save time.
Frequently Asked Questions
What is the cultural significance and history of the Chopped Italian Sandwich in American barbecue cuisine?
The Chopped Italian Sandwich blends classic Italian deli meats with American BBQ techniques, reflecting the immigrant tradition of turning cured meats into hearty, grill‑enhanced meals. It’s popular in backyard cookouts and casual gatherings where the smoky flavor adds a new dimension to a familiar Italian‑style sandwich.
What are the traditional regional variations of the Chopped Italian Sandwich in the United States?
In the Northeast, the sandwich often uses provolone and a mustard‑based dressing, while in the South, BBQ‑style mayo and a sweeter balsamic glaze are common. Some regions swap the French loaf for a hoagie roll or add pickled vegetables like giardiniera for extra tang.
How is the authentic Chopped Italian Sandwich traditionally served in American backyard barbecues?
It is typically presented as a hollowed French or Italian loaf, filled with the chopped, grilled meat mixture, and sliced into individual portions. The sandwich is served at room temperature with a side of chips or a simple green salad.
What occasions or celebrations is the Chopped Italian Sandwich traditionally associated with in American barbecue culture?
It’s a favorite for casual summer cookouts, tailgate parties, and family picnics because it can be prepared in bulk, is easy to eat without utensils, and showcases the grill as the star of the meal.
How does the Chopped Italian Sandwich fit into the broader American barbecue cuisine tradition?
The sandwich exemplifies the American BBQ ethos of taking a classic dish and adding smoky, charred flavors. By grilling cured Italian meats, the recipe merges Mediterranean ingredients with the smoky, communal spirit of American grilling.
What are the authentic traditional ingredients for the Chopped Italian Sandwich versus acceptable substitutes?
Authentic ingredients include salami, pepperoni, ham, provolone cheese, romaine lettuce, tomato, mayonnaise, red wine vinegar, Italian seasoning, balsamic glaze, and pepperoncini. Substitutes can be any cured Italian meats, mozzarella or Swiss cheese, iceberg lettuce, and ranch dressing in place of olive ranch.
What other American barbecue dishes pair well with the Chopped Italian Sandwich?
Pairs nicely with classic sides like coleslaw, baked beans, corn on the cob, or a simple mixed green salad dressed with a light vinaigrette.
What makes the Chopped Italian Sandwich special or unique in American barbecue cuisine?
Its uniqueness lies in grilling cured meats to add crisp texture and smoky flavor, then chopping everything together with a creamy, tangy dressing—creating a sandwich that’s both hearty and refreshing.
What are the most common mistakes to avoid when making the Chopped Italian Sandwich?
Common errors include over‑cooking the meats until they become dry, under‑seasoning the dressing, and using overly soft bread that collapses under the filling. Keep grilling time short, taste the dressing before mixing, and choose a sturdy French loaf.
Why does this Chopped Italian Sandwich recipe use a pellet grill instead of a stovetop pan?
A pellet grill provides even, gentle heat and a subtle wood‑smoke flavor that a stovetop pan can’t replicate, giving the cured meats a light crisp and smoky depth that defines the sandwich’s character.
Can I make the Chopped Italian Sandwich ahead of time and how should I store it?
Yes. Grill the meats and store them in an airtight container in the refrigerator for up to 24 hours. Keep the dressing separate and combine just before assembling. Store the assembled loaf wrapped tightly and consume within 3 days.
What does the YouTube channel allthingsbbq specialize in?
The YouTube channel allthingsbbq focuses on barbecue techniques, product reviews, and creative grill‑centric recipes that blend classic BBQ with global flavors, catering to both beginners and seasoned pitmasters.
How does the YouTube channel allthingsbbq's approach to American barbecue differ from other barbecue cooking channels?
Allthingsbbq emphasizes the use of modern pellet grills, detailed equipment tutorials, and a willingness to experiment with non‑traditional ingredients—like Italian cured meats—while many other channels stick to traditional charcoal or smoker methods.
Last updated: August 30, 2026
