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These BBQ chicken sandwiches are loaded, cheesy, and layered with bold flavor. Shredded grilled chicken gets tossed in a tangy barbecue sauce mixture, stacked onto garlic-butter toasted buns with cheddar and muenster, finished with caramelized red onions and a drizzle of Alabama white sauce. They’re hearty, melty, and perfect for feeding a crowd.
Behind This BBQ Chicken Sandwich Recipe
I love a good BBQ chicken sandwich, but I love it even more when I can make six at once without standing at the stove assembling them one by one. Turning them into a sheet pan meal makes them perfect for game days, family dinners, or anytime you need something hearty and low-effort.
Layering everything in one pan keeps the sandwiches warm, melty, and easy to serve. You can carry the whole tray straight to the table and let everyone grab one.
Tips From My Kitchen
- Use a rimmed sheet pan or 9×13 pan. It keeps everything snug so the sandwiches bake evenly.
- Toast the buns first. Garlic butter + broiler gives structure so they don’t get soggy. Plus it gives these sandwiches much more flavor than plain buns.
- Layer cheese on the bottom. It creates a barrier between the bun and saucy chicken, preventing the buns from getting soggy too quickly.
- Cook the onions low and slow. They should be jammy and sweet, not crispy. They cook in the background while everything else is being prepped.
- Drizzle the white sauce lightly before baking. Serve extra on the side for dipping to avoid making the sandwiches too saucy.
Ingredients You Need & Why
These sheet pan BBQ chicken sandwiches are all about layered flavor. Be sure to review my recipe card at the bottom of the page for detailed measurements.
- Grilled chicken breasts – Adds smoky flavor and shreds easily, so they soak up the sauce.
- Hamburger buns – Soft but sturdy enough to hold the saucy filling. Toasting them with garlic butter adds structure and extra flavor.
- Barbecue sauce – The bold, sweet, and smoky base of the filling.
- Apple cider vinegar – Balances the sweetness, keeping the chicken from tasting too heavy or too sweet.
- Hot sauce – Adds subtle heat and brightness without overpowering.
- Cheddar cheese – Sharp and classic, it adds richness and depth.
- Muenster cheese – Melts smoothly for that gooey, pull-apart texture.
- Red onions – Caramelize into something sweet and jammy, adding contrast to the tangy sauces.
- Garlic butter – Toasts the buns and helps prevent sogginess while adding flavor.
- Alabama white sauce – Creamy and tangy, it cuts through the richness and ties everything together.
How to Make BBQ Chicken Sandwiches
Start by shredding the grilled barbecue chicken breasts into bite-sized pieces. Add them to a bowl with barbecue sauce, apple cider vinegar, and hot sauce. Toss until the chicken is evenly coated and glossy. Add a little more sauce if you prefer it extra saucy.
Preheat your oven to broil. Brush the inside of both the top and bottom hamburger buns with garlic butter. Place them cut-side up under the broiler until golden and lightly crisp around the edges. Watch closely so they don’t burn.
Caramelized Red Onions
While prepping everything else, heat a skillet over medium heat with a drizzle of oil. Add thinly sliced red onions and a pinch of salt. Cook slowly, stirring occasionally, until softened and deep golden brown, about 15–20 minutes. Lower the heat if they begin to brown too quickly. They should be sweet, jammy, and slightly sticky when finished.
Assemble the Sandwiches
Place the six bottom buns side by side in a 9×13 baking dish. Add one slice of cheddar and one slice of muenster to each bun. Divide the shredded BBQ chicken evenly among the sandwiches and drizzle with extra sauce if desired.
Top with a generous layer of caramelized onions and a drizzle of Alabama white sauce. Place the toasted top buns over the sandwiches.
Cover with foil and bake at 375°F for about 20 minutes, or until the cheese is melted and everything is heated through.
Serve warm with coleslaw, chips, or a fresh salad.
How to Serve and Store Leftovers
Serve these sheet pan BBQ chicken sandwiches warm with coleslaw, chips, a green salad, or baked beans.
Store leftovers covered in the refrigerator for up to 3 days. Reheat covered in foil to maintain texture.
Looking for More Sandwich Recipes?
Chicken Chopped Sandwich with Alabama White Sauce
Smashburger Grilled Cheese
Chicken Caesar Salad Sandwich
Italian Grinder Sandwich
Philly Cheesesteak Sliders
BBQ Chicken Sandwich Recipe
Ingredients
BBQ Sandwiches
- 4 grilled chicken breasts shredded (rotisserie works great as a substitute)
- ⅔ cup barbecue sauce
- 2 tablespoons apple cider vinegar
- 1 tablespoon hot sauce
- 6 hamburger buns
- 6 tablespoons garlic herb butter* for brushing
- 6 slices cheddar cheese
- 6 slices muenster cheese
- 1 large red onion thinly sliced
Alabama White BBQ Sauce
- 1¼ cup mayonnaise
- 2 tablespoons apple cider vinegar
- 1 tablespoon dijon mustard
- 2 teaspoons brown sugar
- 2 teaspoons creamy horseradish
- 2 teaspoons fresh lemon juice
- 1 teaspoon Worcestershire sauce
- 2 teaspoons hot sauce
- 1 teaspoon cayenne pepper
- ½ teaspoon garlic powder
- ½ teaspoon onion powder
- salt and pepper to taste
Instructions
Caramelize the onions
- Heat a skillet over medium heat with a drizzle of oil. Add thinly sliced red onions and a pinch of salt.
- Cook, stirring occasionally, for 15–20 minutes until softened, deep golden, and slightly jammy. Reduce heat if they brown too quickly. These can cook in the background while you prep the sandwiches.
Prepare the Filling
- Prepare the Alabama white bbq sauce by whisking all ingredients together in a bowl. Taste and adjust as needed.
- In a large bowl, toss the shredded chicken with barbecue sauce, apple cider vinegar, and hot sauce. Mix until evenly coated. Add more sauce if you prefer a saucier filling.
- Preheat oven to broil. Brush the inside of the top and bottom hamburger buns with garlic butter.
- Place buns cut-side up on a sheet pan and broil for 1–2 minutes, watching closely, until golden brown and lightly crisp.
Assemble and Bake
- Reduce oven temperature to 375°F.
- Arrange the toasted bottom buns snugly on a rimmed sheet pan or 9×13 baking dish.
- Add one slice of cheddar and one slice of muenster to each bun.
- Divide the BBQ chicken mixture evenly among the sandwiches. Drizzle with extra barbecue sauce if desired.
- Top with caramelized onions and a drizzle of Alabama white bbq sauce.
- Place the toasted top buns on, cover loosely with foil, and bake for 20 minutes, until the cheese is melted and the sandwiches are heated through.
- Serve warm with extra Alabama white sauce on the side.
Notes
- For the garlic herb butter, I used Kerrygold. You can also combined 6 tablespoons softened butter with 4 garlic cloves pressed/minced along with minced parsley. Mix to combine.
- Toasting the buns helps prevent sogginess.
- Keep onions on medium-low heat to avoid burning.
- These reheat best covered in foil at 325°F.
