Quick Recipe Version (TL;DR)
Quick Ingredients
- 1 lb (454 g) ground chuck (80/20)
- 1 lb (454 g) ground brisket (or brisket trimmings ground)
- 2 tsp (10 g) kosher salt, divided
- 1 1/2 tsp (3 g) black pepper, divided
- 1 tsp (3 g) smoked paprika
- 1/2 tsp (2 g) garlic powder (optional)
- 2 large yellow onions, very thinly sliced (about 1 lb / 450 g)
- 2 tbsp (28 g) unsalted butter, divided
- 8 slices American cheese (or 8 slices cheddar)
- 4 brioche or potato burger buns
- 1 cup (240 g) mayonnaise
- 1/4 cup (60 g) smoky BBQ sauce
- 1 small garlic clove, finely grated
- 1 tbsp (15 ml) lemon juice
- 1 tsp (5 ml) Worcestershire sauce
- 1 tbsp (15 ml) water (to loosen aioli, optional)
- Neutral oil (as needed for the griddle)
Do This
- 1. Mix chuck + brisket gently; form 8 balls (4 oz / 113 g each). Chill 15 minutes.
- 2. Smoke the balls on a rack at 200°F (93°C) for 25 minutes (just to add smoke, not to cook through).
- 3. Stir together the smoky BBQ aioli; refrigerate.
- 4. Griddle onions in butter over medium-high, 12–15 minutes until soft and browned; keep warm.
- 5. Heat a cast-iron skillet/griddle to 500°F (260°C). Smash balls hard, season, cook 90 sec; flip, add cheese, cook 60 sec.
- 6. Toast buns, spread aioli, stack 2 patties per bun, add onions, serve hot.
Why You’ll Love This Recipe
- Steakhouse-style beefiness at home: brisket + chuck gives deep flavor and great fat for crisp edges.
- Real smashburger crust: a hard smash on a ripping-hot surface creates lacy, crunchy edges.
- Smoke without fuss: a short, low-temp smoke perfumes the meat before the fast sear.
- Cookout “premium” vibes: melty cheese, griddled onions, and smoky BBQ aioli make it feel special.
Grocery List
- Meat: ground chuck (80/20), ground brisket
- Produce: yellow onions, garlic, lemon (optional but recommended)
- Dairy: unsalted butter, sliced American cheese (or cheddar)
- Bakery: brioche or potato burger buns
- Pantry: mayonnaise, smoky BBQ sauce, Worcestershire sauce, smoked paprika, garlic powder (optional), kosher salt, black pepper, neutral oil
- Grilling/Smoking (optional): wood chunks or pellets (oak, hickory, or pecan)
Full Ingredients
Smoked Chuck-and-Brisket Smashburger Blend
- 1 lb (454 g) ground chuck (80/20)
- 1 lb (454 g) ground brisket
- 1 1/2 tsp (8 g) kosher salt (for the patties)
- 1 tsp (2 g) freshly ground black pepper (for the patties)
- 1/2 tsp (2 g) garlic powder (optional)
Griddled Onions
- 2 large yellow onions, very thinly sliced (about 1 lb / 450 g)
- 1 1/2 tbsp (21 g) unsalted butter
- 1/2 tsp (2 g) kosher salt
- 2 tbsp (30 ml) water, as needed to help soften/steam
Smoky BBQ Aioli
- 1 cup (240 g) mayonnaise
- 1/4 cup (60 g) smoky BBQ sauce
- 1 small garlic clove, finely grated (about 1/2 tsp)
- 1 tbsp (15 ml) lemon juice
- 1 tsp (5 ml) Worcestershire sauce
- 1 tsp (3 g) smoked paprika
- 1/2 tsp (2 g) black pepper
- 1 tbsp (15 ml) water, optional (to loosen for easy spreading)
For Cooking & Serving
- Neutral oil (about 1–2 tbsp / 15–30 ml as needed for the griddle)
- 8 slices American cheese (or 8 slices sharp cheddar)
- 4 brioche or potato burger buns
- 1/2 tbsp (7 g) unsalted butter (for toasting buns)
- Optional toppings: dill pickle chips, thin-sliced jalapeños, shredded lettuce
Step-by-Step Instructions
Step 1: Make the beef blend and form smashburger balls
In a large bowl, combine 1 lb (454 g) ground chuck and 1 lb (454 g) ground brisket. Use clean hands to mix just until the two meats look evenly combined—avoid overworking, which can make burgers dense.
Portion into 8 balls, 4 oz (113 g) each. Roll lightly (don’t pack them tight). Place on a parchment-lined tray, cover, and refrigerate for 15 minutes while you prep everything else. Starting cold helps you get a better crust and cleaner smash.
Step 2: Stir together the smoky BBQ aioli
In a small bowl, whisk until smooth:
1 cup (240 g) mayonnaise, 1/4 cup (60 g) smoky BBQ sauce, 1 grated garlic clove, 1 tbsp (15 ml) lemon juice, 1 tsp (5 ml) Worcestershire, 1 tsp (3 g) smoked paprika, and 1/2 tsp (2 g) black pepper.
If you like a looser, super-spreadable sauce, whisk in 1 tbsp (15 ml) water. Cover and refrigerate until serving (at least 10 minutes is great).
Step 3: Smoke the burger balls for a quick “kiss of smoke”
Preheat your smoker to 200°F (93°C). Add wood suited for beef—oak, hickory, or pecan are all excellent.
Set the chilled burger balls on a wire rack or perforated grill tray so smoke can circulate. Smoke at 200°F (93°C) for 25 minutes. You’re not trying to cook them through; you’re adding smoke flavor before the fast smash sear.
Timing note: Keep the balls cold going into the smoker. After smoking, move straight to the hot griddle step so they don’t linger in the temperature danger zone.
Step 4: Griddle the onions until soft, sweet, and browned
Heat a large skillet or griddle over medium-high heat. Melt 1 1/2 tbsp (21 g) butter, then add the sliced onions and 1/2 tsp (2 g) kosher salt.
Cook, stirring often, for 12–15 minutes until the onions are softened with browned edges. If the pan looks dry or the onions start to scorch, splash in 1–2 tbsp (15–30 ml) water and scrape up the flavorful browned bits.
Transfer onions to a bowl and cover to keep warm.
Step 5: Preheat the griddle or cast iron until ripping hot
Set a large cast-iron skillet, flat-top griddle, or steel plancha over high heat until the surface reaches 500°F (260°C). This usually takes 5–8 minutes depending on your setup.
Lightly oil the surface with neutral oil (a thin sheen is enough). Have ready: a sturdy metal spatula (or a burger press), a small square of parchment for smashing, and your cheese slices unwrapped.
Step 6: Smash, season, and cook the patties fast for crisp edges
Working in batches (don’t overcrowd), place 2–4 smoked burger balls on the hot surface.
Immediately cover each ball with a parchment square and smash hard with your spatula/press for a full 10 seconds until very thin. Remove parchment.
Season the top of each patty with a portion of: 1 1/2 tsp (8 g) kosher salt, 1 tsp (2 g) black pepper, and 1/2 tsp (2 g) garlic powder (if using). Aim to season right after smashing so it adheres.
Cook the first side for 90 seconds until deeply browned with lacy edges. Use the spatula to scrape underneath (get that crust), then flip.
Immediately add 1 slice cheese to each patty. Cook the second side for 60 seconds.
Doneness: Smashburgers are typically cooked through. For best food safety, the stacked burger should reach 160°F (71°C) in the thickest area. Because patties are thin, this happens quickly.
Step 7: Toast buns and assemble premium cookout burgers
Spread 1/2 tbsp (7 g) butter across the cut sides of the buns. Toast cut-side down on the griddle for 60–90 seconds until golden.
To assemble each burger: spread 1–2 tbsp smoky BBQ aioli on the bottom bun, add 2 cheesy smash patties, pile on a generous spoonful of griddled onions, and add optional pickles. Cap with the top bun and serve immediately while the edges are crisp and the cheese is fully melty.
Pro Tips
- Cold meat, hot surface: Chill the balls and fully preheat to 500°F (260°C) for the best crust and clean flip.
- Smash once, then leave it alone: Smash for 10 seconds and don’t press again later (pressing after the crust forms squeezes out juices).
- Use parchment to prevent sticking: A small parchment square between spatula and meat keeps your press from grabbing the patty.
- Scrape to keep the crust: Use a thin, sturdy metal spatula and scrape firmly when flipping to keep the browned layer attached.
- Smoke is optional, but the flavor isn’t: If you don’t have a smoker, increase smoked paprika in the aioli to 1 1/2 tsp and use a lightly toasted bun for extra depth.
Variations
- Spicy BBQ smashburgers: Add 1–2 tsp hot sauce to the aioli and top with pickled jalapeños.
- Texas-style: Swap onions for pickled red onions and add a thin layer of BBQ sauce under the top bun.
- Extra smoky: Smoke the onions too: place sliced onions in a foil pan and smoke at 200°F (93°C) for 20 minutes, then finish on the griddle with butter.
Storage & Make-Ahead
Best fresh: Smashburgers are at their peak right off the griddle (that crisp edge softens as they sit).
Make ahead: Mix and portion burger balls up to 24 hours ahead; keep tightly covered in the refrigerator. The BBQ aioli can be made up to 5 days ahead and refrigerated in a sealed container.
Leftovers: Store cooked patties and onions separately in airtight containers for up to 3 days. Reheat patties on a hot skillet over medium-high heat for 1–2 minutes per side to revive some crispness; reheat onions in the same pan for 2–3 minutes.
Nutrition (per serving)
Approximate, for 1 double-patty burger with bun, cheese, onions, and aioli: 1050 calories; 58 g protein; 72 g fat; 43 g carbohydrates; 6 g sugar; 3 g fiber; 1650 mg sodium.
