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

  1. 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

  2. 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

  3. 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

  4. 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

  5. Add Cheese

    Stir in the shredded provolone cheese, distributing it evenly.

    Time: PT1M

  6. Make the Dressing

    In a small cup, whisk together mayonnaise, red wine vinegar, Italian seasoning, balsamic glaze, and olive ranch dressing.

    Time: PT1M

  7. Combine Everything

    Pour the dressing over the meat‑cheese‑vegetable mixture. Toss thoroughly until everything is evenly coated.

    Time: PT2M

  8. 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

  9. 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

  10. 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

Last updated: April 16, 2026

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Chopped Italian Sandwich Recipe for the Yoder Smokers YS640s – Ultimate Meat-Lover’s Sub!

Recipe by allthingsbbq

A hearty, BBQ‑style Italian sandwich packed with grilled salami, pepperoni, ham, cheese, fresh romaine, tomato, and a tangy mayo‑vinegar dressing, all piled into a hollowed French loaf and garnished with pepperoncini. Perfect for a casual lunch or dinner with friends.

EasyAmerican (Barbecue) with Italian influencesServes 6

Shop all ingredients on Amazon in one click • Printable PDF with shopping checklist

Source Video
10m
Prep
16m
Cook
10m
Cleanup
36m
Total

Cost Breakdown

$47.37
Total cost
$7.90
Per serving

Critical Success Points

  • 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.

Safety Warnings

  • Handle the hot grill with heat‑resistant gloves and use long tongs.
  • Be careful when chopping with a sharp knife; keep fingers tucked.
  • Ensure cooked meats reach an internal temperature of at least 145°F for safety.

Frequently Asked Questions

Everything you need to know about this recipe

Q

What is the cultural significance and history of the Chopped Italian Sandwich in American barbecue cuisine?

A

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.

cultural
Q

What are the traditional regional variations of the Chopped Italian Sandwich in the United States?

A

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.

cultural
Q

How is the authentic Chopped Italian Sandwich traditionally served in American backyard barbecues?

A

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.

cultural
Q

What occasions or celebrations is the Chopped Italian Sandwich traditionally associated with in American barbecue culture?

A

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.

cultural
Q

How does the Chopped Italian Sandwich fit into the broader American barbecue cuisine tradition?

A

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.

cultural
Q

What are the authentic traditional ingredients for the Chopped Italian Sandwich versus acceptable substitutes?

A

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.

cultural
Q

What other American barbecue dishes pair well with the Chopped Italian Sandwich?

A

Pairs nicely with classic sides like coleslaw, baked beans, corn on the cob, or a simple mixed green salad dressed with a light vinaigrette.

cultural
Q

What makes the Chopped Italian Sandwich special or unique in American barbecue cuisine?

A

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.

cultural
Q

What are the most common mistakes to avoid when making the Chopped Italian Sandwich?

A

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.

technical
Q

Why does this Chopped Italian Sandwich recipe use a pellet grill instead of a stovetop pan?

A

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.

technical
Q

Can I make the Chopped Italian Sandwich ahead of time and how should I store it?

A

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.

technical
Q

What does the YouTube channel allthingsbbq specialize in?

A

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.

channel
Q

How does the YouTube channel allthingsbbq's approach to American barbecue differ from other barbecue cooking channels?

A

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.

channel

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