How to Make Barbecue Chicken Sandwiches: A Step-by-Step Recipe for Juicy, Flavor-Packed Bites

Barbecue chicken sandwiches are a summer classic that never go out of style.

Whether you're planning a cookout or just want a satisfying weeknight dinner, this easy BBQ chicken sandwich recipe brings the smoky-sweet flavor you crave — without fuss.

In this guide, we’ll walk you through exactly how to make barbecue chicken sandwiches that are tender, juicy, and full of bold BBQ flavor.

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What You’ll Need

Before we jump into how to make barbecue chicken sandwiches, here’s what you’ll want on hand:

• Boneless chicken breasts or thighs

• Your favorite BBQ sauce (store-bought or homemade)

• Buns (brioche, potato rolls, or sandwich buns work best)

• Toppings including coleslaw, pickles, and red onions

• Butter or oil for grilling

• Optional: cheese slices and extra BBQ glaze

Step 1: Grill the Chicken (or Use Leftovers)

The flavor starts with well-cooked chicken.

You can grill it fresh or use leftover BBQ chicken.

Grilling adds char and smoky depth.

How to Grill Fresh Chicken

• Preheat your grill to medium heat (about 375°F).

• Lightly coat the chicken with oil and season with salt and pepper.

• Place it on the grill and cook 5–7 minutes per side, or until internal temp hits 165°F.

• In the last few minutes, baste with BBQ sauce and flip for a caramelized finish.

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Step 2: Shred or Slice the Chicken

Once the chicken is cooked and slightly cooled, you can either:

• Shred it using two forks (great for a pulled BBQ texture), or

• Slice it thinly if you prefer bigger bites

Add a bit more warm BBQ sauce to coat the meat thoroughly before assembling.

Step 3: Toast the Buns

Toasted buns hold up better to saucy chicken and add a slight crunch.

Here’s how to do it:

• Butter the insides of each bun

• Place them cut-side down on the grill or skillet for 1–2 minutes

• Toast until golden and lightly crisp

Step 4: Assemble the Sandwiches

Now comes the fun part. Stack it all together:

• Bottom bun

• A generous pile of BBQ chicken

• Optional toppings: creamy coleslaw, pickles, thin red onion, or cheese

• Extra drizzle of sauce (optional)

• Top bun

You’re done!

Serve hot with fries, corn on the cob, or a cold drink.

Bonus Tip: Make It in Advance or Use Leftovers

These sandwiches are also great made from leftover grilled or smoked chicken.

Just reheat the meat in a pan with BBQ sauce until warmed through.

This is an easy way to transform yesterday’s cookout into today’s lunch or dinner.

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Final Thoughts

Knowing how to make barbecue chicken sandwiches from scratch gives you endless flexibility.

Grill fresh or use leftovers, pick your favorite sauce, and build it your way.

It's fast, flavorful, and perfect for summer.

And don’t forget — using the right tools makes grilling easier.

Click the image below to check out our grill-safe cleaning tools and explore our full range of BBQ accessories designed to make every cookout easier and safer.