If there’s a dish that practically belongs at Kentucky Derby gatherings, it’s this Grilled Kentucky Hot Brown on the Big Green Egg. Stacked with smoked turkey, crisp sweet-and-spicy bacon, grilled tomato, and a silky Mornay sauce, this open-faced sandwich is comforting, indulgent, and elevated by the grill.
The classic Kentucky Hot Brown from Louisville is a long-standing favorite, and my wife grew up eating it as part of that regional tradition. Bringing the recipe to the Big Green Egg adds a hint of live-fire smoke, crisped bread, and a slightly caramelized finish that an oven can’t replicate. Whether you’re making this for Derby Day, weekend brunch, or a casual dinner, it’s memorable, impressive, and easier to prepare than it looks.
Preparing the Turkey
For this version I used boneless, skinless turkey breasts instead of holiday leftovers. They’re easy to work with and slice beautifully for open-faced sandwiches.
Season the breasts simply with kosher salt and black pepper—there’s no need for heavy seasoning since the Mornay sauce, bacon, and tomato provide plenty of flavor.
To keep the meat tender and juicy I cooked the breasts sous vide at 140°F for 2½ hours after vacuum-sealing. This method yields even doneness edge to edge and prevents drying when you slice the turkey for the sandwich. After sous vide, pat the turkey dry and transfer it to the Big Green Egg briefly to pick up light smoke and attractive color. Let it rest before slicing thin for the Hot Brown.
Making the Pig Candy Bacon
Great bacon is essential. For this recipe I make “pig candy”: thick-cut bacon coated with brown sugar and spices, cooked low and slow until sticky and crisp.
Set the Big Green Egg for indirect heat at about 300°F. Combine brown sugar, black pepper, and a touch of cayenne, then press the mixture onto thick-cut bacon slices. Arrange the bacon on a rack and cook for 30–40 minutes, until caramelized and crisp. In the last five minutes brush with maple syrup for a glossy finish. Let the bacon cool slightly before using—it should be sweet, smoky, and crisp.
Grilling the Tomatoes and Bread
After the bacon, raise the Egg to about 350°F to grill tomatoes and toast the bread. The higher temperature softens the tomatoes quickly and crisps the bread for structure.
Toss tomato wedges with olive oil, kosher salt, and black pepper. Brush thick slices of Italian bread with melted butter and season lightly. Place the tomatoes and bread directly on the grate—tomatoes need only a few minutes to soften and char slightly, while the bread develops good grill marks and stays sturdy enough to hold the toppings.
Making the Mornay Sauce
The Mornay sauce is the defining element: a smooth, cheesy béchamel that unites the sandwich.
Melt 1 tablespoon butter in a medium saucepan over medium heat, whisk in 1 tablespoon all-purpose flour to form a roux, then slowly add 1 cup 2% milk while whisking constantly. Season with salt and 1/4 teaspoon black pepper. Cook, stirring frequently, until the sauce thickens and coats the back of a spoon—about 5 minutes. Remove from heat and stir in 1/4 cup freshly grated Parmigiano-Reggiano until the sauce is silky and smooth. Take your time here; a lump-free, creamy sauce makes the sandwich exceptional.
Assembling the Kentucky Hot Brown
When all components are ready, finish the sandwiches using the residual heat in the Egg. Close the vents to remove active direct heat and rely on the gentle warmth to melt the sauce and heat everything through without burning.
In a cast-iron pan, arrange the grilled Italian bread, top with sliced turkey and grilled tomato wedges, and pour the warm Mornay sauce generously over each open-faced sandwich. Return the pan to the Big Green Egg for 10–15 minutes until the sauce is hot, bubbly, and lightly browned. Finish with the pig candy bacon on top and serve the sandwiches directly from the pan for a rustic presentation that keeps them hot and satisfying.
Grilled Kentucky Hot Brown on the Big Green Egg
Equipment
- Cast Iron Pan
Ingredients
Mornay Sauce Ingredients:
- 1 tbsp butter
- 1 tbsp all-purpose flour
- 1 cup 2% milk
- 1/4 tsp black pepper
- 1/8 tsp salt
- 1/4 cup grated Parmigiano-Reggiano
Bacon Ingredients:
- 1 lb thick-cut bacon
- 1/2 cup brown sugar
- 1/2 tsp black pepper
- 1/2 tsp cayenne pepper
- 1/4 cup maple syrup
Sandwich Ingredients:
- 2 lbs turkey breasts, boneless & skinless
- Salt & pepper, to taste
- 2 large tomatoes, cut into wedges
- 2 tbsp olive oil
- 4 slices Italian bread, thick cut
- Salt & pepper, for seasoning bread and tomatoes
Instructions
Mornay Sauce:
- Melt butter in a saucepan over medium heat, whisk in flour to form a smooth roux.
- Slowly add milk while whisking, season with salt and pepper, and cook about 5 minutes until thickened.
- Remove from heat and stir in grated Parmigiano-Reggiano until smooth and creamy.
Bacon Instructions:
- Preheat the Big Green Egg to 300°F for indirect cooking. Mix brown sugar, black pepper, and cayenne, then coat the bacon slices evenly.
- Place bacon on a rack and cook 30–40 minutes until crisp and caramelized. In the last 5 minutes brush with maple syrup.
- Remove and let cool slightly before adding to the sandwiches.
Turkey Instructions:
- Season turkey breasts with kosher salt and black pepper, vacuum seal, and cook in a 140°F sous vide bath for 2½ hours.
- Remove from bag, pat dry, and preheat the Big Green Egg to 350°F for direct cooking.
- Grill the turkey briefly—about 2–3 minutes per side—to add smoke and color.
- Let rest 10 minutes, then slice thin for the sandwiches.
Bread & Tomatoes Instructions:
- Toss tomato wedges with olive oil, kosher salt, and black pepper.
- Brush both sides of Italian bread with melted butter and season lightly.
- Grill tomatoes and bread at 350°F until tomatoes are lightly charred and bread is toasted with grill marks.
Sandwich Assembly:
- Close the Egg’s vents to remove active direct heat and use the residual heat to finish the sandwiches.
- In a cast-iron pan, layer grilled bread, sliced turkey, and tomato wedges. Pour warm Mornay sauce over each open-faced sandwich.
- Return the pan to the Egg for 10–15 minutes until the sauce is hot, bubbly, and lightly browned. Top with pig candy bacon and serve hot from the pan.
Nutrition information is an approximation and should be used only as a guideline.