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Sausage Melt with American Cheese and Caramelized Onions

Celebrity Chef Mark McEwan gives the classic melt a mouth-watering makeover. Follow this easy recipe to transform a simple sandwich into a handheld masterpiece you can call your own. It’s a sandwich so good, it’ll make you, well, melt.

Prep Time
Cook Time

What You Need

  • 1 pkg. (17.64 ounces/500 g) Johnsonville Original Bratwurst Sausage, casings removed
  • 1 tbsp sriracha
  • 1 tsp fresh thyme, minced
  • 1 garlic clove, minced
  • 1/4 cup bread crumbs
  • 1/8 tsp black pepper
  • 4 burger buns
  • 8 slices of American style cheese
  • 2 tbsp good quality BBQ sauce
  • 4 tbsp butter, divided
  • 1 yellow onion, skins removed and julienned
  • 2 tbsp butter
  • 1 tsp kosher salt


  1. In a sauté pan, melt 2 tbsp of butter on medium high heat. Add the onion then salt. Cook approximately 20 minutes, frequently stirring, until the onions are deep brown and sweet. Remove and cool.

  2. Mix the sausage meat, sriracha, thyme, garlic, bread crumbs, and pepper until well combined. Then divide the meat into 4 equal size patties.Grill the patties until cooked through. While the patties are cooking, lightly base each patty with the BBQ sauce. When the patties are fully cooked, place them on a plate to cool, slightly, so the melt can be built.

  3. While patties are cooking, pull each bun apart to create 8 pieces. Flip each piece over so the top and bottom of each bun is facing you. Using a rolling pin, roll each half bun to flatten slightly.

  4. To build the melts, place one slice of cheese on the bottom bun followed by the patty, 1 tbsp of caramelized onions and then another slice of cheese. Generously butter the top and bottom of all the melts. Cook each melt in a non-stick pan on medium heat until both sides are golden brown and crispy. Be sure to gently press down the melt on both sides until cooked. A spatula or frying pan will do the trick.