How to Make a BBQ Fatty (Bacon-Wrapped Sausage Roll)
A BBQ fatty is one of those cooks that sounds complicated but is actually one of the easiest things…
A BBQ fatty is one of those cooks that sounds complicated but is actually one of the easiest things you can throw on a smoker. You take cheap bulk sausage, roll it around some fillings, wrap the whole thing in a bacon weave, and smoke it until it’s done. The result looks like something from a competition BBQ booth, and it costs a fraction of what you’d spend on a brisket or pork shoulder.
If you’re looking for a crowd-pleasing showpiece that fits a tight grocery budget, this is it. Bulk breakfast or Italian sausage is one of the most affordable meats for protein you’ll find at any grocery store, and when you wrap it in bacon and smoke it low and slow, it punches way above its weight class.
Disclosure: As an Amazon Associate, this site earns from qualifying purchases. Thank you!
What Is a BBQ Fatty?
The fatty has been a backyard BBQ staple for years, especially in the competition circuit. At its most basic, it’s just a log of ground sausage smoked until done. The stuffed version, sometimes called a “stuffed fatty,” adds a layer of fillings rolled up inside the sausage before the bacon wrap goes on.
Don’t let the bacon weave intimidate you. It’s just an over-under pattern, the same thing you’d do with paper strips in grade school. Once you do it once, it takes about three minutes the next time around.
Choosing Your Sausage and Bacon
Standard bulk pork breakfast sausage is the classic choice and it’s usually the cheapest option on the shelf. Jimmy Dean, store brand, whatever is on sale, it all works. You want something with decent fat content so it doesn’t dry out during the cook.
Italian sausage (hot or mild) is another excellent choice and gives you a more savory, herb-forward base that pairs well with peppers and cheese. You can also use a 50/50 mix of breakfast sausage and ground pork if you want to stretch your dollar even further.
For bacon, regular thin-cut strips are actually easier to weave than thick-cut. Thick-cut looks impressive but takes longer to render and can end up chewy if your cook time isn’t long enough. Stick with standard-cut bacon for a cleaner result.
Bacon Press for Even Cooking
A cast iron bacon press helps keep your weave flat and in contact with the sausage during the early part of the cook.
Stuffing Ideas: What to Put Inside
This is where the fatty gets fun. Almost anything that works on a pizza or sandwich works inside a fatty. The key rule is to keep your fillings relatively dry. Too much moisture and the sausage won’t hold its shape when you slice it.
Classic Combinations
- Jalapeño and cream cheese with shredded cheddar. This is the crowd favorite for a reason. It’s rich, a little spicy, and the cream cheese keeps everything together.
- Pepperoni, mozzarella, and pizza sauce. Go light on the sauce to avoid sogginess. It tastes exactly like a pizza log and disappears fast at parties.
- Caramelized onions and Swiss cheese. Simple, savory, and excellent for people who don’t want a lot of heat.
- Scrambled eggs, hash browns, and cheddar. This one makes a killer breakfast fatty for weekend morning cooks.
Upgraded Options
- Spinach, sun-dried tomatoes, and feta. A Mediterranean twist that works surprisingly well with mild Italian sausage.
- BBQ pulled pork and pickled jalapeños. If you have leftover pulled pork sitting in the fridge, this is an excellent use for it.
- Green chiles and pepper jack. Southwest-style fatty with good heat and a melty interior.
- Mushrooms, garlic, and provolone. Umami-forward and a great pairing with Italian sausage base.
Whatever you choose, pre-cook anything that releases moisture, like mushrooms, peppers, or onions. Raw vegetables steam inside the fatty and make the interior soggy and loose.
How to Roll and Wrap It
Start with about 1.5 to 2 pounds of bulk sausage. Lay a sheet of plastic wrap or parchment paper on your counter and press the sausage out into a flat rectangle, roughly 10 by 12 inches and about a quarter inch thick. Even thickness matters here so the sausage cooks uniformly.
Spread your fillings across the sausage, leaving about an inch of bare sausage on all edges. This border seals the ends when you roll. Use the parchment paper to help you roll the sausage tightly into a log shape, pinching the ends closed like a burrito. Set it in the fridge for 15 to 20 minutes to firm up before you weave the bacon around it.
Building the Bacon Weave
- Lay out six to eight strips of bacon vertically on a flat surface.
- Fold back every other strip halfway down.
- Lay one strip horizontally across the unfolded strips.
- Unfold the folded strips over the horizontal strip, then fold back the alternate strips.
- Repeat with remaining horizontal strips until you have a tight weave.
Place your sausage roll at the edge of the weave and roll it up, tucking the ends of the bacon underneath. It doesn’t need to be perfect. As long as the bacon is covering the sausage, it’ll look great after the cook.
Instant Read Meat Thermometer
An instant-read thermometer is the only way to know when your fatty has hit a safe internal temperature without guessing.
Smoking the Fatty
Set your smoker to 225°F to 250°F. Hickory, apple, and cherry wood all work well. Hickory gives you a stronger smoke flavor that complements the bacon. Apple and cherry are milder and let the filling flavors come through more.
Place the fatty seam-side down directly on the grate. Smoke it until the internal temperature hits 165°F, which usually takes two to two and a half hours depending on your cooker and the thickness of your roll. If you need a good fuel choice, check out this breakdown of lump charcoal vs briquettes for smoker fuel options.
Don’t rush it with high heat. The bacon needs time to render properly or it’ll be rubbery. Low and slow is what makes the weave crisp up and turn that deep mahogany color that makes people pull out their phones for photos.
Rest the fatty for 10 minutes before slicing. Use a sharp knife and slice it into half-inch rounds. The spiral cross-section is the whole visual payoff. This is also a great addition to a spread if you’re planning a cookout, and it fits naturally alongside other ideas in a backyard BBQ party setup.
Wood Smoking Chips
Having a variety of smoking wood on hand lets you match the smoke flavor to whatever fillings you’re using.
Serving and Leftover Ideas
Sliced fatty rounds work well on a platter alongside crackers, pickles, and cheese, almost like a warm version of a charcuterie board spread. They also reheat well the next day in a skillet, and the slices make an excellent addition to breakfast sandwiches or eggs.
Leftovers keep in the fridge for three to four days. You can also freeze individual slices wrapped in foil for quick lunches later in the week.
Frequently Asked Questions
Can I make a fatty without a smoker?
Yes. You can cook a fatty in the oven at 300°F on a wire rack set over a baking sheet. It won’t have smoke flavor, but the bacon will still render and crisp up nicely. Add a little smoked paprika to your sausage to approximate some of that smoke character. Some people also use a grill set up for indirect heat, which works well and adds light smoke if you add a chunk of wood to one side.
Why did my fatty fall apart when I sliced it?
This usually means the roll wasn’t tight enough, or the fillings were too wet. Make sure you pre-cook any vegetables, drain off excess liquid, and roll the sausage firmly with no air pockets. Chilling the rolled sausage before wrapping it in bacon also helps it hold its shape during the cook.
What size sausage roll should I use?
Most fatties are made with 1.5 to 2 pounds of bulk sausage. A two-pound roll feeds about six people as an appetizer or four people as a main. If you’re feeding a bigger crowd, make two smaller rolls instead of one giant one. They’ll cook more evenly and be easier to manage on the grill.
This article contains affiliate links. We may earn a small commission at no extra cost to you.
