I love a sandwich that tastes like a street food hero and comes together fast — that’s what this Grilled Choripan Sausage Burger delivers. It’s a smoky, spicy chorizo patty tucked into a toasted bun with tangy chimichurri aioli and quick-pickled onions. I’ve tested this on a gas grill and a cast-iron skillet and learned how small technique changes up the flavor and texture.
Why Make This Recipe
- Big flavor: spicy, smoky chorizo plus bright chimichurri gives a perfect flavor contrast.
- Fast and satisfying: from raw sausage to bun in about 15–20 minutes on the grill.
- Great for gatherings: easy to scale up for cookouts or weeknight dinners.
- Flexible toppings: works with cheese, pickles, slaws, or a grilled-cheese mashup like a cheeseburger-grilled-cheese fusion I tried recently (great for indulgent weeknights) — https://www.meinlabradorretriever.com/cheeseburger-grilled-cheese-fusion-2/.
Personal note: I love this because it tastes like a street sandwich but uses simple tools and pantry ingredients.
Recipe Overview
Prep time: 10 minutes.
Cook time: 8–12 minutes.
Total time: 20 minutes.
Servings: 4 burgers (from 1 lb chorizo).
Difficulty: Easy.
Method: Form fresh chorizo into patties and grill or pan-sear over medium-high heat until the internal temperature reaches 160°F, then toast buns and assemble.
If you prefer oven or small appliances, you can adapt the cook method like I’ve done with similar handheld sandwiches — see this air fryer cheeseburger wraps idea for inspiration — https://www.meinlabradorretriever.com/air-fryer-cheeseburger-wraps/.
My Experience Making This Recipe
The first time I made choripan as a patty I overpacked the meat and it came out dense; loosening the patties and keeping them slightly loose created juicier results. I also tested a quick chimichurri aioli (mayonnaise + chimichurri) that keeps the sandwich from drying out.
How to Make Grilled Choripan Sausage Burger
Start with 1 lb fresh pork chorizo (remove casings if in links). Gently form into four patties about 3/4-inch thick — handle them lightly so they don’t compact. Preheat a gas or charcoal grill to medium-high (about 400–450°F) or heat a cast-iron skillet over medium-high on the stovetop.
Grill the patties 4–6 minutes per side, flipping once, until an instant-read thermometer reads 160°F in the center. Toast buns for 30–60 seconds on the grill cut-side down. Assemble with chimichurri aioli, grilled onions, and pickles or queso fresco. If you need ideas for scaling to a crowd, I’ve used similar approaches when adapting recipes like an Amish hamburger casserole for feed-a-lot menus — https://www.meinlabradorretriever.com/amish-hamburger-casserole/.
Expert Tips for Success
- Use fresh chorizo (uncooked) rather than cured chorizo; it fries and grills like ground pork and stays juicy.
- Don’t overwork the meat: form patties with light pressure so you keep air pockets that help juiciness.
- Use an instant-read thermometer: pull patties at 160°F for food safety and best texture.
- Manage flare-ups: move patties to indirect heat if fat drips and flames spike, then finish with a quick sear.
- Cheese pairing: melt a mild provolone or Oaxaca over the patty for creaminess; I often borrow ideas from grilled cheese combos like this BBQ chicken pineapple grilled cheese for inspiration on balancing sweet and spicy — https://www.meinlabradorretriever.com/bbq-chicken-pineapple-grilled-cheese/.
How to Serve Grilled Choripan Sausage Burger
- Classic: Toasted brioche or potato roll, chimichurri aioli, quick-pickled red onions, and cilantro.
- Cheesy: Add melted provolone or a slice of Monterey Jack and a smear of mustard for extra richness; you can even nestle it into a grilled-cheese style sandwich for weeknight fun — see a grilled-cheeseburger fusion for inspiration — https://www.meinlabradorretriever.com/cheeseburger-grilled-cheese-fusion/.
- Party setup: serve build-your-own toppings (sliced chiles, aiolis, slaws) so guests customize.
Presentation tip: stack toppings deliberately — sauce on both bun halves helps keep the patty moist and prevents sogginess on the bottom.
Storage and Reheating Guide
Refrigerate cooked patties in an airtight container for 3–4 days. Freeze cooked patties wrapped tightly in plastic and placed in a freezer bag for up to 2–3 months. For uncooked formed patties, freeze on a tray then transfer to bags for up to 3 months; thaw overnight in the fridge before cooking.
Reheat refrigerated patties in a skillet over medium for 3–4 minutes per side until warmed to 140°F, or in a 350°F oven for 6–8 minutes covered with foil. For frozen patties, thaw fully before reheating. Microwave reheating works in a pinch but can make the sausage dense; cover and use short bursts, then finish in a hot skillet for texture.
Recipe Variations
- Gluten-free: use a gluten-free bun or lettuce wrap and check chimichurri aioli ingredients for gluten-free mayo.
- Dairy-free: skip the cheese and use a dairy-free mayo or chimichurri to keep it creamy.
- Spicy-sweet: top with grilled pineapple or a mango salsa for a sweet contrast.
- Link to casserole-style option: if you want a layered, oven-baked version for crowds try transforming the flavors into a tray casserole similar to other hamburger bakes you may like.
Nutritional Highlights
- Protein-forward: chorizo provides a hearty protein boost per serving, good for active adults.
- Higher in fat: fresh chorizo is fatty and flavorful; balance with bright herbs and veggies on the bun.
Allergen info: contains pork and may contain dairy if you add cheese or aioli with dairy-based ingredients. Adjust portions and toppings to manage calories — one patty plus a bun is a satisfying single serving.
Troubleshooting Common Issues
- Patties falling apart: that usually means the meat was too loose or wet; gently pat dry with paper towel and chill 15–20 minutes before grilling to help them hold shape.
- Over-charred exterior but raw inside: grill too hot or patties too thick. Lower to medium heat (350–400°F) and use a thermometer to finish cooking to 160°F.
- Soggy bun: apply sauce to both bun halves and toast buns well; place moisture-heavy toppings between cheese and bun to act as a barrier.
Frequently Asked Questions
Q: Can I make choripan patties ahead and freeze them?
A: Yes. Form patties, freeze them on a sheet tray until firm (about 1 hour), then move to a sealed freezer bag for up to 3 months. Cook from thawed for even cooking; you can cook from partially frozen if you increase time and use a thermometer.
Q: Can I use chorizo links instead of forming patties?
A: Absolutely. Split links lengthwise and grill cut-side down for 3–4 minutes, or cook whole and slice into burgers. Whole links will take slightly longer and you still want an internal temp of 160°F.
Q: What if my chorizo is very spicy — how can I tone it down?
A: Balance heat with cooling toppings: a plain mayo, crema, or a yogurt-based slaw reduces perceived heat. Adding some honey or grilled pineapple also mellows spice while adding complexity.
Q: Is chimichurri aioli necessary?
A: It isn’t necessary but it adds acidity and herb brightness that cuts through the fat. You can swap for mustard, plain mayo, or salsa verde if you prefer.
Conclusion
If you want a ready-made idea for a piquant sauce to pair with grilled chorizo patties, this recipe for Grilled Chorizo Burgers with Chimichurri Aioli offers a great reference and inspiration — Grilled Chorizo Burgers with Chimichurri Aioli – Plan to Eat (https://www.plantoeat.com/blog/2022/05/grilled-chorizo-burgers-with-chimichurri-aioli/).
Grilled Choripan Sausage Burger
- Total Time: 20 minutes
- Yield: 4 servings
- Diet: Pork
Description
A smoky, spicy chorizo patty tucked into a toasted bun with tangy chimichurri aioli and quick-pickled onions, delivering big flavor in just 20 minutes.
Ingredients
- 1 lb fresh pork chorizo
- 4 hamburger buns
- Chimichurri aioli
- Quick-pickled red onions
- Cilantro
- Optional: Cheese (provolone, Monterey Jack), mustard, grilled pineapple
Instructions
- Remove casings from the chorizo if using links and gently form into four patties about 3/4-inch thick.
- Preheat grill to medium-high (about 400–450°F) or heat a skillet over medium-high.
- Grill patties for 4–6 minutes per side, flipping once, until an instant-read thermometer reads 160°F.
- Toast buns on the grill, cut-side down, for 30-60 seconds.
- Assemble the burger with chimichurri aioli, grilled onions, and pickles or queso fresco.
Notes
Avoid compacting the chorizo patties for juicier results. Use fresh, uncooked chorizo for the best texture.
- Prep Time: 10 minutes
- Cook Time: 10 minutes
- Category: Main Course
- Method: Grilling
- Cuisine: Latin American