For some, grilling season is sort of like culinary cosplay: get some fancy tools, slap on an apron, and pile the grill high with meats and veggies that will all somehow transform into charcoal by the time the day's over. For others, it's a state of mind: an alfresco cooking experience where the art of cooking meets thermodynamic science and the primordial urge to roast protein over fire.
Our juicy links offer a common ground between these two mindsets. That's because grilling The Sausage Project’s chicken sausages is remarkably straightforward: our Classic Roasted, Italian Herb, and Melty Cheddar links are pre-cooked and ready to eat with minimal prep. That means they're easy enough for armchair pitmasters to prepare without ruining them, yet complex and flavorful enough for the Alton Browns of the world to finesse into something transcendent.
Still, keeping a few tricks in your apron when grilling sausages—pre-cooked or otherwise—can make a huge difference. Knowing how to grill chicken sausage correctly is one of the easiest ways to improve your results.
To help you earn your grill master stripes in time for your next backyard cookout, we polled our team of chefs and outdoor-cooking enthusiasts for tips on grilling the perfect sausage. From overlooked prep work to simple pro tips, they’ll add some sizzle to your next BBQ.
Let Sausages Come to Room Temp Before Grilling
It’s tempting to pull sausages straight from the fridge and toss them onto the grill. That’s technically fine, but you’re not maximizing juiciness. As with any meat, let sausages come to room temp for 30–60 minutes before grilling. This ensures even cooking and amplifies those juicy, satisfyingly snappy bites.
Oil Sausages for Better Browning and No Sticking
In the world of grilled meats, there are few tragedies more avoidable than ripped sausage casings caused by sticking to hot grates. Our natural casing is strong and browns beautifully, but a bit of oil really helps them deliver. Lightly brush sausages with a high smoke point oil (like avocado or canola) before they hit the grill. This prevents sticking and promotes even browning—plus that golden crispness.
Use Heat Zones for Juicier Grilled Sausages
Think of your grill like a museum of fire—curated heat zones let you sear, roast, and finish to perfection. On a gas grill, it’s as easy as adjusting burner levels. Charcoal? Just shift the coals into hot and cold areas.
These zones are the key to keeping your sausages snappy. "Start them on the medium-heat side of the grill and let them cook through gradually,” says Mike Nugent, CEO and pit master at Dinosaur Bar-B-Que. “Once they’re nearly done, move them over to the hot side to develop a nice, flavorful char on the outside. By cooking them gently and finishing with high heat, you’ll get a juicy interior and a crisp exterior.”
Braise Sausages for a Big Flavor Boost
Fully cooked sausages don’t need to be boiled—but braising is a power move if you want to infuse extra flavor before or after the grill. Try simmering your links in beer, apple cider, or broth with aromatics before finishing them on the grill. It deepens the flavor and makes our already juicy sausages even juicier.
Add Smoky Flavor to Sausages on Any Grill
Even pre-cooked sausages benefit from a kiss of smoke. On a charcoal grill, toss a chunk of wood or soaked wood chips onto the coals before moving your sausages to indirect heat. On a gas grill, use a smoker box or make a DIY smoker pouch by wrapping soaked wood chips in foil and poking a few holes in the top. Hickory or applewood add a subtle, savory smoke that plays beautifully with chicken sausage.
Use Tongs, Not Forks
We get it—grilling forks look cool, but your tastebuds don’t care about a photo op. Piercing perfectly grilled sausage will do nothing more than send delicious juices into the inferno below. Use tongs or a spatula and keep that goodness sealed inside.
Glaze Your Sausages for Caramelized Flavor
Once your sausages are mostly cooked, add a brush of something bold. Maple syrup, hot honey, or a swipe of mustard glaze can caramelize beautifully on the casing. It’s a fast way to add flavor—and earn some grilling cred.
Grill Our Chicken Sausages Lightly
Casual grillers get really worried about food temps. It’s well intentioned, but usually results in burger pucks, bone-dry chicken, and sausage that would work better as kindling than dinner. Fully cooked sausages need only be warmed and browned on the grill, not incinerated. You’re grilling them for texture, warmth, and extra flavor. A few minutes is all you need. Anything more is a recipe for disappointment.
Rest Grilled Sausages for Better Flavor
Temptation will really push you to snap right into your sausages immediately, burned palate be damned. But exercising just a little bit of patience reaps rewards. Simply rest grilled sausages for 2–3 minutes before serving. It lets juices redistribute for a more flavorful, cleaner bite. A small price to pay for a couple sausageless minutes.
MORE: For even more info about the extremely important art of managing grill heat, check out these tips from grill masters.