Are you in the mood for a chicken sandwich that’s smoky, juicy, and dripping with sweet, tangy BBQ flavor? If so, you’re going to love this Grilled Chicken Sandwich recipe. I teamed up with my buddy Richard Fergola, of Fergolicious BBQ, to make a sandwich that’s loaded with flavor and perfect for those backyard hangs or weeknight meals when you want to impress without the hassle.

We used boneless, skinless chicken thighs, layered on two of our favorite rubs, and finished it all off with Heath Riles BBQ Sweet BBQ Sauce for that irresistible glaze. Whether you're a seasoned grillmaster or just breaking in your Weber Kettle Grill 22", this is an easy win that delivers every time.

Grilled BBQ Chicken Sandwiches on the Weber | Cooking With Friends – Richard Fergola

This recipe is a great introduction to two-zone grilling. You get that hot, crispy sear right over the coals, followed by indirect heat to keep the meat juicy and tender. With bold rubs and a caramelized BBQ finish, this sandwich punches well above its weight.

The Ingredients

Here’s what we used to season, glaze, and build our chicken sandwiches:

Boneless, Skinless Chicken Thighs – Juicy and forgiving on the grill, these are perfect for a flavorful, moist sandwich. Trim off any excess fat for even cooking.
Duck Fat Spray – Adds richness and helps the rubs adhere to the meat while delivering a hint of smoky flavor.
Heath Riles BBQ Garlic Jalapeño Rub – A bold seasoning with savory garlic and a little jalapeño heat to give the chicken some bite.
Fergolicious BBQ Butter Pecan Rub – Sweet, buttery, and nutty. It balances the spice and rounds out the flavor profile.
Heath Riles BBQ Sweet BBQ Sauce – Our go-to glaze for a sticky, caramelized finish with sweet and tangy notes.
Sandwich Buns – We used soft, sandwich-style buns, but brioche or potato rolls would be perfect too.
Mayonnaise – Adds creamy richness and helps balance the heat.
Heirloom Tomato Slices – Fresh and juicy for contrast.
Lettuce – For crunch and freshness.
Pickles – Classic sandwich topper for some acid and snap.
Red Onion – Adds sharpness and color to round out each bite.

The Smoker Setup

Here’s what I used for this cook. You’ll find more of my trusted grilling essentials in the Equipment and Tools section below.

Grill. I used the Weber Kettle 22" for this recipe. It’s a backyard classic with the versatility to go from high-heat searing to low-and-slow cooking with just a simple two-zone setup. Perfect for anything from quick weeknight cooks to long, smoky sessions on the weekend.

Fuel. I fired up the grill with Royal Oak Super Size Hickory Blended Pellet Charcoal Briquets. These all-natural briquets are infused with real hickory wood pellets, giving you the consistent heat of charcoal with the added depth of hardwood smoke—all in one step. No need to toss in extra wood. Just light and let them work their magic.

The Process for Making Grilled BBQ Chicken Sandwiches

You can catch the full video with Ferg and me cooking side-by-side, but here’s how we built these next-level sandwiches from start to finish:

1. Trim and Prep the Chicken

Lay out your thighs and trim off excess fat and any loose flaps of meat. This step helps the chicken cook more evenly and look better in the sandwich.
Pro tip: Don’t toss those trimmings—save them for jambalaya or render the fat for homemade chicken grease.

2. Layer on the Flavor

Spray each thigh with Duck Fat Spray on both sides. This not only adds richness but also helps lock in the smoke and hold the rub.

Start with a heavy layer of Heath Riles Garlic Jalapeño Rub , then come over the top with Butter Pecan Rub. Flip the chicken and repeat. You want full coverage for a deep, layered crust.

3. Get the Grill Hot

With your Weber Kettle set up for a two-zone fire, place the chicken directly over the hot coals. Grill for about 3 minutes per side to build color and sear.

Once you’ve got good caramelization, move the thighs to the cooler side of the grill. Cover the lid and cook for another 15–20 minutes until they reach 165°F internally.

4. Glaze and Finish

In the final minutes of cooking, brush both sides of the chicken with Heath Riles Sweet BBQ Sauce. Let it set over indirect heat to caramelize. Flip and glaze again for that thick, glossy finish.

Build It Your Way

Once the chicken’s off the grill, it’s time to stack your sandwich. Everyone builds theirs a little different, and that’s part of the fun.

Ferg went with a double stack of chicken thighs, lettuce, tomato, pickles, red onion, and an extra drizzle of sauce. I kept mine simple: mayo on both buns, a few fresh tomato slices, and a final dusting of rub.

Whatever your style, it’s hard to go wrong with this kind of flavor.

The Results

These sandwiches were off-the-charts good. The Garlic Jalapeño Rub gave it a bold, savory base, the Butter Pecan Rub brought a sweet finish, and the Sweet BBQ Sauce tied it all together with a sticky, smoky glaze. The chicken was tender, juicy, and full of flavor from edge to edge.

It’s everything you want in a backyard BBQ sandwich—crispy edges, saucy finish, and layers of flavor in every bite.

Serving Suggestions for Grilled Chicken Sandwiches

Want to make this a complete BBQ plate? Pair your sandwiches with one (or more!) of these crowd-pleasing sides from our recipe collection:

Pit-Style BBQ Baked Beans – Slow-cooked beans with smoky depth and sweet BBQ flavor. These are a backyard essential.
Creamy Coleslaw – Cool, crisp, and tangy—perfect for balancing the heat and richness of the sandwich.
Heath’s Potato Salad – A classic Southern-style side dish that’s creamy, comforting, and easy to whip up.
Smoked Mac & Cheese – Rich, gooey, and kissed with smoke—this mac and cheese could steal the show.

Add your favorite cold drink, and you've got a plate that’s ready to impress at any cookout.

Storing Leftovers

If you’ve got leftovers, here’s how to keep them fresh:

Fridge – Store cooked chicken in an airtight container for up to 4 days.
Freezer – Wrap tightly and freeze for up to 2 months.
Reheat – Warm gently in a 300°F oven with a splash of water or sauce, or reheat on the grill to refresh the texture.