Smoky Grilled Meatball Subs: The Ultimate Summer Sandwich

Experience a bold twist on a beloved classic with these Grilled Meatball Subs, featuring perfectly charred meatballs, sweet and savory BBQ sauce, caramelized grilled onions, and gooey melted cheese, all nestled in crusty artisan rolls.

Get ready to elevate your summer grilling game! While the classic meatball sub is a winter comfort food staple, we’re taking it outdoors and transforming it into a sun-soaked sensation. This recipe for Grilled Meatball Subs isn’t just a meal; it’s an experience, bringing smoky flavors and a delightful char that only a grill can provide. And if you’ve been following along, you’ll know this dish pairs impeccably with our Bacon Bourbon Barbecue Sauce – a combination so good, it’s practically legendary in our kitchen. Of course, a high-quality bottled sauce works wonderfully too, but the homemade version truly takes these subs to another level.

Consider this the grand reveal. After perfecting our rich, smoky barbecue sauce, these grilled meatball subs were the natural next step. We’ve meticulously crafted every element, from the tender, flavorful meatballs to the perfectly grilled onions, ensuring each bite is an explosion of taste and texture. Forget what you thought you knew about meatball subs; this summer-ready version is about to become your new favorite.

Winter Warmth Meets Summer Sizzle: The Grilled Meatball Sub Revolution

When the colder months arrive, few things beat the comforting embrace of traditional meatballs. Slow-simmered in a rich marinara, served over pasta, tucked into manicotti, or piled high on an Italian roll with a blanket of melted mozzarella, they evoke a deep sense of warmth and home. These dishes are timeless for a reason, offering hearty satisfaction during chilly evenings.

However, as temperatures rise and the days lengthen, our culinary cravings shift. The grill calls, and with it, an opportunity to reinvent classics. Our grilled meatballs offer a refreshing departure from their winter counterparts. Instead of a gentle simmer, these meatballs take a journey to the grill, emerging with a beautiful, light char that adds a layer of smoky complexity and a wonderfully crisp exterior. This grilling method imparts a distinct flavor profile, perfectly complementing the sweet and tangy notes of barbecue sauce.

Imagine: succulent, lightly-charred meatballs, sweet and tender grilled onions, a generous slathering of rich BBQ sauce, and a topping of creamy, melted cheese, all packed into a crusty artisan roll. It’s a vibrant, fresh, and undeniably bold take on the meatball sub, designed specifically for summer entertaining. These subs are robust, bursting with flavor, and ideal for enjoying al fresco gatherings, backyard barbecues, or any occasion that calls for delicious, no-fuss food.

Crafting the Perfect Meatball: Ingredients & Technique

Developing this grilled meatball recipe has been a labor of love over nearly a decade, starting with an initial inspiration from a Williams-Sonoma grilling basket. While that gadget was certainly fun for achieving perfectly spherical meatballs, rest assured, it’s by no means a necessity for this recipe. Our focus here is on flavor and texture, ensuring every meatball is moist, tender, and incredibly delicious.

The Secret to Tender Meatballs: The Panade

The key to exceptionally tender meatballs lies in the use of a panade – essentially, bread cubes soaked in milk. This simple technique prevents the meatballs from drying out on the grill, ensuring they remain juicy and succulent. Don’t skip this step; it makes all the difference in achieving that desired melt-in-your-mouth texture.

The Ideal Meat Blend and Seasoning

For optimal flavor and fat distribution, we recommend a blend of ground beef (85%/15% lean is perfect) and ground pork. This combination yields a richer taste and keeps the meatballs wonderfully moist. Beyond the meats and panade, fresh ingredients elevate the overall profile. Finely chopped Italian parsley brings a bright, herbaceous note, while fresh thyme leaves add an aromatic depth that pairs beautifully with the smoky elements of grilling and barbecue sauce. Simple kosher salt and freshly-ground black pepper are essential for seasoning, bringing out the natural flavors of the meats.

Choosing Your Cheese

While the original recipe might have called for Provolone, we’ve found that an aged White Cheddar truly shines in this context, especially when paired with a robust barbecue sauce like our Bacon Bourbon variant. The sharp, creamy notes of cheddar complement the smokiness and slight sweetness of the sauce without being overpowering. However, don’t hesitate to experiment! We’ve also had fantastic results with Gouda, Gruyere, and Emmental, each offering a unique twist to the overall flavor profile. Choose your favorite melting cheese to complete your sub.

Prepping for the Grill

Once your meatball mixture is gently combined (remember, overworking can lead to tough meatballs!), shape them into uniform portions. A light chill in the refrigerator for about 30 minutes helps them firm up, making them easier to handle on the grill and ensuring they retain their shape beautifully as they cook. This small step contributes significantly to perfectly grilled meatballs.

Assembling Your Epic Meatball Sub

The grand finale of this culinary journey is the assembly. This isn’t just about putting ingredients together; it’s about layering flavors and textures to create a cohesive, satisfying sandwich. Start by toasting your crusty rolls lightly on the grill. This adds a subtle crunch and prevents them from becoming soggy under the weight of the delicious fillings.

Next, spoon a generous amount of warm barbecue sauce onto the bottom half of each roll. Layer with your perfectly grilled, caramelized onions, followed by a trio of those smoky, tender meatballs. Finally, top each with a slice of sharp cheddar cheese. Return the assembled subs to the grill (with the heat off, or very low) with the lid closed for a few minutes. This gentle heat will melt the cheese into a glorious, gooey blanket, uniting all the elements into one magnificent bite. The aroma alone is enough to make your mouth water!

Flavorful Variations & Serving Suggestions

These grilled meatball subs are incredibly versatile. While sharp cheddar is our top pick, feel free to experiment with other cheeses like smoked provolone for an extra smoky kick, or even Monterey Jack for a milder, creamier melt. For those who enjoy a bit of heat, a sprinkle of red pepper flakes into the meatball mixture or a dash of hot sauce over the finished sub can add a welcome zing. You could also experiment with different barbecue sauces – a spicier variety or one with a fruitier profile could offer exciting new dimensions.

When it comes to serving, remember these are not dainty sandwiches. They are robust, hearty, and unapologetically messy – in the best possible way! Embrace the delicious drips and grab a stack of moist towelettes. For the perfect pairing on a warm afternoon, a crisp, cold beer is highly recommended. A Saison, with its fruity and spicy notes, complements the richness of the subs beautifully, as one of our guests can attest. Alternatively, a refreshing iced tea or a light, effervescent lemonade would also be fantastic companions. Serve alongside a simple green salad, some crispy coleslaw, or even grilled corn on the cob for a complete summer meal.

As summer draws to a close, there’s no better time to fire up the grill and savor these incredible sandwiches. Don’t let grilling season slip away without experiencing this bold, flavorful take on a classic. Get ready for an unforgettable meal!

Rating: 5 out of 5 stars (from 1 vote)

Grilled Meatball Subs

by
Amanda Biddle

Grilled Meatball Subs layer lightly-charred meatballs with grilled onions, BBQ sauce, and melted cheese onto crusty rolls for a bold take on a classic.

Adapted from Williams-Sonoma Kitchen

Prep Time:
30 minutes

Cook Time:
40 minutes

Total Time:
1 hour 10 minutes

Servings:
4 large sandwiches (3 meatballs per sandwich)

Ingredients

• 2 slices white bread (about 1 cup), crusts removed, bread cut into 1/2-inch cubes
• ¼ cup milk
• 2 medium yellow onions
• 1 tablespoon olive oil
• kosher salt
• freshly-ground black pepper
• 2 tablespoons chopped Italian parsley
• 1 teaspoon chopped fresh thyme leaves
• ¾ pound ground beef (85%/15%)
• ¼ pound ground pork
• 2 cups barbecue sauce (bottled or homemade, such as our Bacon Bourbon sauce recipe)
• 4 crusty sandwich rolls
• 4 slices sharp cheddar cheese

Instructions

1. In a large bowl, pour milk over bread cubes and toss until moistened. Set aside. Finely chop 1/2 of an onion (about 1 cup). In a small sauté pan over medium heat, cook chopped onions in 1 tablespoon olive oil until softened and just beginning to brown, about 5-8 minutes. Cool slightly.
2. Stir cooked onions, 1 teaspoon kosher salt, 1/2 teaspoon pepper, parsley, and thyme into the moistened bread cubes until thoroughly combined. Crumble ground beef and pork into the bread mixture and gently combine with a fork until incorporated. (Overworking the meat mixture until it resembles a paste will result in tough meatballs.)
3. With lightly damp hands (or an ice cream scoop), shape meatballs into 12 equal portions, about 3 tablespoons each. Cover and refrigerate about 30 minutes, until chilled.
4. Heat grill over medium-high flame for 10 to 15 minutes. Oil grates or line with nontoxic, nonstick grill mats.
5. Slice remaining onions into 1/2-inch thick slices. Brush onions with olive oil and lightly season with a few pinches of salt and pepper. Grill onions over direct heat until softened and well-browned, about 5 minutes per side, turning occasionally.
6. Grill meatballs over direct heat until well-browned, about 3-5 minutes per side.
7. Pour barbecue sauce into a grill-safe dish or foil pan. Add browned meatballs and gently turn to coat. Lower the flame, close the grill lid, and continue cooking until the sauce is hot and the meatballs register 160 degrees F.
8. Cut sandwich rolls in half lengthwise and grill, cut side down, over a low flame, until lightly toasted. Layer rolls with barbecue sauce, grilled onions, meatballs, and sliced cheddar cheese. Turn off the heat and return the assembled subs to the grill, lid closed, until the cheese is melted.

Nutrition Estimate

Calories: 912 kcal | Carbohydrates: 100g | Protein: 35g | Fat: 40g | Saturated Fat: 15g | Cholesterol: 111mg | Sodium: 2096mg | Potassium: 857mg | Fiber: 4g | Sugar: 52g | Vitamin A: 820IU | Vitamin C: 8.4mg | Calcium: 388mg | Iron: 5.7mg

Nutrition information is automatically calculated, so should only be used as an approximation.

About our recipes

Please note that our recipes have been developed using the US Customary measurement system and have not been tested for high altitude/elevation cooking and baking.