BBQ Bacon Sandwich with Roasted Peppers and Provolone

^{This post has been sponsored by Andria's Food Group. All opinions expressed are my own.}

This isn't your average BLT. Now, I love the classic combo of bacon, lettuce, and tomato as much as anyone else, but there's also no denying that sometimes you want to switch things up a little - while still sticking to the same, delicious formula that's made us all fall in love with the classic BLT. This is a gourmet, loaded and layered reimagining of the tried-and-true BLT. The secret weapon here is Andria's Barbecue Sauce - a rich, tangy, and perfectly balanced sauce that takes this sandwich from "delicious" to "I'm making this every weekend" territory.

So how exactly is this sandwich so deliciously different from the standard BLT? For starters, we're brushing the bacon with Andria's Barbecue Sauce and then cooking the bacon in the oven until perfectly crispy (more on this process below). Then we layer roasted peppers, provolone, and thinly sliced red onion onto toasted club rolls. This creates a BLT that's sweet and smoky and richly satisfying.

This sandwich is substantial enough to serve as a light summer dinner on the weekend and won't wither under the spotlight if served as the main event to guests at a casual warm-weather get-together. Whether you're hosting friends for lunch or just treating yourself to something special, this BBQ bacon sandwich will deliver every single time. Read on for a printable recipe card, a complete ingredient checklist, a crispy bacon technique guide, and assembly tips.

Jump to:

• How to Make the Perfect BBQ Bacon Sandwich
• Complete Ingredient Checklist
• Essential Equipment
• Equipment for Today's Recipe
• Tips for the Best BBQ Bacon Sandwich
• BBQ Bacon Sandwich with Roasted Peppers and Provolone

How to Make the Perfect BBQ Bacon Sandwich

This sandwich can be boiled down to a few key techniques: properly crispy bacon, bread that stands up to the filling, perfectly melted cheese, and an assembly order that prevents sogginess. Here's how we nail each step.

Step 1: Cook the Bacon on a Wire Rack

This is how we achieve restaurant-quality bacon. Preheat the oven to 375 degrees F. Set a wire rack inside a rimmed baking sheet (do NOT skip the baking sheet; otherwise, the bacon grease will drip into the oven elements and burn). The wire rack allows the grease to drip safely - keyword 'safely' - off the bacon as it cooks. If the bacon is allowed to cook in its own grease, it becomes soggy because the fat causes it to steam in its own juices.

Arrange the bacon slices on the wire rack in a single layer (avoid overlapping). Now brush with Andria's Barbecue Sauce. This is the secret trick that will instantly elevate today's sandwich. Brushing the bacon with the sweet and savory BBQ sauce almost 'candies' it for an irresistible result.

Now bake the bacon for 15-20 minutes until it reaches a deep golden brown color and meets your preferred level of crispiness. No flipping required. Thicker bacon takes longer. Check the bacon at the 15-minute mark and continue checking in 2-minute increments. Transfer the bacon to a paper-lined plate to absorb any excess oil. Crispy bacon, no greasy bread.

Step 2: Toast the Club Rolls (optional, but recommended)

This is completely optional and comes down to preference. However, toasting the bun helps guard against a soggy sandwich and also helps ensure that the roll stands up to the ingredients. We start by slicing each club roll horizontally, and then we toast lightly just until golden. I wouldn't recommend toasting past golden; otherwise, the roll will be so toasty that it becomes the overriding texture of the sandwich - which is not what we want for this particular recipe.

💡 Pro-Tip: If the rolls are very soft or have a thin crust, brush the cut sides with olive oil before toasting.

Step 3: Melt the Cheese

Place 4 slices of provolone on the bottom half of each toasted club roll, then return to the oven or toaster oven for 30-60 seconds at 375 degrees F until the cheese is melted. We want the cheese just gooey enough that it acts as an anchor for the rest of the sandwich, but not so melted that it runs everywhere. Basically, the cheese needs to still be firm enough that it acts as a moisture guard for the bread.

Step 4: Assemble the Sandwich

If you've ever wondered why deli sandwiches come out so good - it's in the assembly. No, seriously, there is an art to assembling a sandwich. Even the very best ingredients cannot overcome poor assembly technique.

I recommend layering the sandwich in this sequence: Bottom of the roll, then the melted cheese, then the BBQ-glazed bacon, then the romaine, then the roasted peppers, then the tomato slices, then the red onion, and then we close with the top of the roll.

Why this Assembly Order Works:

• Lettuce Against Cheese: This prevents the BBQ sauce from soaking into the bread.
• Roasted Peppers: These add an irreplaceable smoky-sweet flavor without making the lettuce soggy.
• Bacon in the Middle: This distributes the crunch evenly throughout the sandwich.
• Tomato Above the Bacon: This allows the juices to flow through the other layers of the sandwich rather than directly into the bread.
• Red Onion on Top: Best position for an oniony bite, since it allows the other flavors to meet your taste buds first.
• Finish Technique: Press the sandwich gently on closing, then slice if desired and serve immediately while the cheese is warm and the bacon fresh.

Complete Ingredient Checklist

• 1 lb Bacon
  • Thick Cut or Regular Cut? I strongly recommend using thick-cut bacon, as it provides the ideal balance of crispiness without losing its meaty bite.
  • How many slices? 1 pound of bacon yields approximately 12-16 slices. I recommend 3-5 slices per sandwich.
  • Dry-Cured: Look for dry-cured bacon, as other varieties contain too much added water. Check the packaging.
  • Flavor? Applewood-smoked, hickory-smoked, or maple-cured will all work beautifully and will deliciously complement Andria's Barbecue Sauce.
  • How Crispy? This is a preference. While I recommend cooking the bacon until very crisp but not dry, if you prefer your bacon softer side - go for it. As in most recipes, some things really do come down to preference, and this is one of them.
  • Substitute: Turkey Bacon is probably the most popular substitute. Canadian would also work. Pancetta, however, would be my go-to substitute due to its saltier flavor and overall richer profile. If you want to keep this recipe meatless, you can always opt for your preferred vegetarian bacon.
• 1 cup Andria's Barbecue Sauce
  • Not-So Secret Ingredient: The star of the show, Andria's Barbecue Sauce, transforms today's sandwich from a BLT with a twist into something truly crave-worthy.
  • Balance is Key: Andria's Barbecue Sauce brings sweet and tangy complexity with rich, smoky undertones that deliciously complement the bacon - but it does so without being aggressively sweet or overwhelmingly tangy like some other commercially available barbecue sauces, nor does it drown you in smoke.
  • Side: Serve some of the barbecue sauce on the side for dipping fries, chips, or even the sandwich itself.
• 2 Heirloom Tomatoes, sliced thin
  • Why Heirloom Tomatoes? Heirloom tomatoes bring a mix of substantial bite, a sweeter flavor, and an overall more complex flavor than do regular tomatoes.
  • Ripe, but firm: I recommend choosing tomatoes that are ripe but still firm. Having the tomatoes hold together on the sandwich is key not only for the flavor but also to prevent the tomato from sogging into the sandwich.
  • Substitute: Your tomato of choice, really. I would recommend beefsteak tomatoes, Roma tomatoes, or vine-ripened tomatoes.
• Roasted Peppers
  • Flavor Depth: The roasted peppers are foundational in this recipe by bringing smoky-sweet depth to the sandwich and rich color.
  • Homemade or Store-Bought? If you have a gas range, I would recommend making them homemade by roasting them directly over the flame. Otherwise, I would opt for store-bought.
  • Substitute: Your peppers of choice, or omit them entirely in favor of extra bacon.
• Sliced Provolone Cheese (or your favorite cheese)
  • Why Provolone? A couple of reasons, the primary one being its mild flavor, which complements, rather than competes with, the other ingredients. Provolone also melts really well but without becoming overly gooey. It also brings undeniable Italian-American flair to the sandwich, especially when used alongside the roasted peppers.
  • Can I use a different cheese? Absolutely. The type of cheese is mostly a preference.
  • Substitutes: Use the cheese of your choice, but my go-to alternatives would be mozzarella, pepper jack, smoked gouda, or Jarlsberg.
  • Avoid: I would recommend against crumbly cheeses such as feta, since they don't melt properly. I would also avoid processed American cheese, as it lacks flavor and usually has a distinct, overwhelming quality to it, especially in terms of texture. No hate, I love a good American Cheese grilled cheese as much as the next person, but this is just not a sandwich that plays to its qualities.
• 1 small Red Onion
  • Slice thin: I recommend slicing the onion as thinly as possible. This helps keep the flavor and texture delicate.
  • Why red onion? Red onions are generally the go-to onions for raw or lightly cooked recipes - sandwiches included. It also adds a small pop of color.
  • Substitute: Sweet onions such as Vidalia or Walla Walla would be the ideal substitute, in my opinion. That said, any onion will work. You can, of course, omit entirely.
• Romaine Lettuce
  • Why Romaine? I find that romaine lettuce has a nice crisp texture for sandwiches while also holding up really well. It also brings a subtle-yet-unmissable balance of savory vegetal or herbal flavors.
  • Substitute: Any lettuce. Iceberg would be my go-to; it's crunchier but also milder. Butter lettuce can work, but its more tender texture risks fraying in the sandwich.
• Club Rolls
  • Substantial Structure: Club rolls hold up well even when piled high with fillings. The bready interior and typically thick crust also mean that they hold up well to moisture.
  • Substitute: Ciabatta rolls are a great alternative. Brioche buns can work, but are slightly sweet for this recipe, and unless toasted, they are very sensitive to moisture. Pretzel rolls, Sourdough rolls, or thickly sliced Italian bread all work for this recipe.
  • Avoid: Hot dog buns and hamburger buns, as most varieties are simply too small - though you can of course scall back the fillings to make it work. Avoid white sandwich bread, as it will simply fall apart.

Essential Equipment

• Wire Rack
  • Essential (Sort of): While I strongly recommend using a wire rack to cook the bacon to ensure even, optimal crispiness, cooking the bacon stovetop in a cast iron pan, or directly on a baking sheet, will by no means ruin this recipe.
  • Caution: Do NOT cook the bacon on a wire rack 'unless' you put it in a rimmed baking sheet to catch the fat, which will otherwise drip directly into the oven.
• Rimmed Baking Sheet
  • For the Wire Rack: The rimmed baking sheet is absolutely essential for safely cooking the bacon on the wire rack.
  • Or Making the Bacon: If you don't have a wire rack, you can also cook the bacon directly in the rimmed baking sheet.
• Cutting Board
  • For Cutting (what else?): For slicing the ingredients, you'll need a decent, sturdy cutting board. Personally, I prefer hard maple or walnut. Hardwood is generally considered the gold standard for cutting boards

Equipment for Today's Recipe

Baking and Cooling Rack

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Stainless Steel Baking Sheet

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Wooden Cutting Board

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Tips for the Best BBQ Bacon Sandwich

1. Achieving Perfectly Crispy Bacon: Don't crowd the wire rack. Give the slices space to crisp evenly. For extra-crispy results, use thick-cut bacon and extend the cooking time to 20-25 minutes. The fat needs time to render fully, so do not try to rush this step.
2. Best Bread Choices: The bread matters perhaps as much as the bacon, since the bread is the deciding factor in texture and how well the sandwich holds together. Club roles are my go-to as they are pretty much the ideal shape and size, and they hold together amazingly well. Other great choices include brioche buns, ciabatta, or potato rolls. Avoid sandwich bread for this recipe. Regardless of the bread you choose, I recommend toasting.
3. Keeping the Bacon Crispy: Add the bacon as one of the last components, just before serving. If you're making these sandwiches ahead, keep the bacon separate until ready to eat. The lettuce barrier between the cheese and the moist ingredients also helps to prevent the moisture from soaking through into the bacon.
4. Cheese Melting Guidelines: For provolone, 375°F for 30-60 seconds is the sweet spot for this recipe. Any hotter or longer would make the cheese much too liquid. If using a harder cheese, like aged cheddar, add an extra 30 seconds. We want the cheese soft, not running off the bread.

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And that's our BBQ Bacon Sandwich with Roasted Peppers and Provolone! If you enjoyed today's recipe or have any questions or suggestions, be sure to let us know in the comments below; we always love hearing from you. And, as always, be sure to try out Andria's line of sauces and salad dressing! I promise you won't be disappointed.

Happy Cooking!

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