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Smoked Bourbon Chicken Sandwich

Smoked Bourbon Chicken Sandwich

This smoked bourbon chicken sandwich is made with juicy smoked chicken thighs, sticky bourbon BBQ glaze, creamy slaw, crispy onions, and toasted brioche buns. The smoke gives the chicken deep flavor while the bourbon BBQ glaze adds a sweet, smoky finish. Creamy slaw and crispy onions bring crunch, freshness, and balance.
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Prep Time 25 minutes
Cook Time 1 hour 45 minutes
Total Time 2 hours 10 minutes
Course Main Course
Cuisine American, BBQ
Servings 6
Calories 750 kcal

Equipment

  • Smoker or pellet grill
  • Instant-read thermometer
  • Small saucepan
  • Silicone basting brush
  • Mixing bowls
  • Cutting board
  • Chef knife
  • Tongs
  • Heat-resistant gloves
  • Black nitrile gloves, optional
  • Grill or griddle for toasting buns

Ingredients
  

For the Smoked Chicken:

  • 6 boneless skinless chicken thighs
  • 1 tablespoon olive oil or yellow mustard
  • 2 tablespoons BBQ rub
  • 1 teaspoon kosher salt only if your BBQ rub is low-salt or salt-free
  • 1/2 teaspoon black pepper
  • 1/2 teaspoon garlic powder
  • 1/2 teaspoon smoked paprika

For the Bourbon BBQ Glaze:

  • 1 cup BBQ sauce
  • 1/4 cup bourbon
  • 2 tablespoons brown sugar or honey
  • 2 tablespoons apple cider vinegar
  • 1 tablespoon Worcestershire sauce
  • 1 tablespoon Dijon mustard or yellow mustard
  • 1/2 teaspoon garlic powder
  • 1/2 teaspoon smoked paprika
  • 1 pinch cayenne pepper optional
  • 2 tablespoons butter

For the Creamy Slaw:

  • 3 cups coleslaw mix
  • 1/2 cup mayonnaise
  • 1 tablespoon apple cider vinegar
  • 1 tablespoon honey
  • 1 teaspoon Dijon mustard
  • 1/2 teaspoon celery seed optional
  • 1/2 teaspoon kosher salt
  • 1/4 teaspoon black pepper

For the Sandwiches:

  • 6 brioche buns
  • 2 tablespoons butter for toasting buns
  • 1 1/2 cups crispy fried onions
  • Extra bourbon BBQ glaze for serving
  • Pickles optional

Alcohol-Free Glaze Option:

  • Replace the bourbon with apple juice peach nectar, unsweetened tea, or extra BBQ sauce.

Instructions
 

  • Prep the smoker. Preheat your smoker or pellet grill to 275°F using cherry, apple, pecan, or hickory wood.
  • Season the chicken. Pat the chicken thighs dry. Coat lightly with olive oil or yellow mustard, then season with BBQ rub, black pepper, garlic powder, smoked paprika, and salt if needed.
  • Start smoking the chicken. Place the chicken thighs on the smoker and cook until they reach about 145°F to 155°F internal temperature.
  • Make the bourbon BBQ glaze. While the chicken smokes, add BBQ sauce, bourbon, brown sugar or honey, apple cider vinegar, Worcestershire sauce, mustard, garlic powder, smoked paprika, and cayenne to a small saucepan. Simmer over medium-low heat for 8 to 10 minutes, stirring often. Stir in butter at the end until glossy.
  • Make the slaw. In a mixing bowl, combine mayonnaise, apple cider vinegar, honey, Dijon mustard, celery seed, salt, and pepper. Add the coleslaw mix and toss until coated. Refrigerate until ready to use.
  • Glaze the chicken. Brush the chicken thighs with bourbon BBQ glaze once they reach about 145°F to 155°F. Close the lid and keep cooking until the glaze gets tacky.
  • Finish the chicken. Continue smoking until the chicken thighs reach 175°F to 185°F for best texture. Chicken should reach at least 165°F for food safety.
  • Rest the chicken. Remove the chicken from the smoker and let it rest for 5 minutes.
  • Toast the buns. Butter the brioche buns and toast them on a grill, griddle, or skillet until golden.
  • Build the sandwiches. Add creamy slaw to the bottom bun, place a smoked bourbon glazed chicken thigh on top, drizzle with extra glaze, add crispy fried onions, and finish with the top bun.
  • Serve. Serve warm with pickles, fries, BBQ beans, coleslaw, chips, or your favorite backyard BBQ sides.

Notes

Boneless chicken thighs work best because they stay juicy and tender.
Do not glaze too early or the sugar in the glaze can darken too much.
Simmer the glaze before brushing it on the chicken so it thickens and turns glossy.
Use a silicone basting brush instead of a paint-style brush.
Toast the buns so they hold up to the slaw and glaze.
Add crispy onions right before serving so they stay crunchy.
Use cherry wood for great color and mild sweet smoke.
For a stronger BBQ flavor, use pecan or a small amount of hickory.
For an alcohol-free glaze, replace bourbon with apple juice, peach nectar, unsweetened tea, or extra BBQ sauce.
Store leftover chicken, slaw, crispy onions, and buns separately.
Reheat chicken gently in the oven, smoker, or air fryer until hot.
Keyword BBQ chicken sandwich, bourbon BBQ chicken, bourbon chicken sandwich, smoked bourbon chicken sandwich, smoked chicken sandwich, smoked chicken thighs