Saucy Rossy BBQ
Sausage

Jalapeño Cheddar Smoked Sausage from Scratch

From-scratch pork sausages loaded with jalapeños and cheddar, stuffed into natural casings, cured overnight, and slowly smoked for a perfect snap and juicy texture.

TimeOvernight + 6 hrs Yield1 kg batch CategorySausage Watch6:08
Jalapeño Cheddar Smoked Sausage from Scratch — watch on YouTube

Watch the full cook on YouTube

Method

  1. 1Grind the pork if it isn't already ground — a medium grind works well — and mix the BBQ seasoning, kosher salt, and curing salt together in a small bowl.
  2. 2Add the seasoning mixture and 150–200 ml of ice-cold water to the pork, then mix thoroughly until the meat becomes sticky and tacky to build the protein bind that gives sausage its firm texture.
  3. 3Gently fold in the diced jalapeños and cubed cheddar, mixing just enough to distribute them evenly.
  4. 4Stuff the mixture into the soaked, rinsed hog casings with a sausage stuffer, avoiding air pockets and taking care not to overstuff, then twist into links.
  5. 5Rest the links uncovered in the refrigerator overnight (8–12 hours) so the cure distributes, the casings dry slightly, and the smoke adheres better.
  6. 6Start the smoker at 150°F and slowly increase the temperature every hour — 150, 160, 170, 180, 190, then 200°F — over about 6 hours to gently cook the sausage without breaking the casing or melting out the cheese.
  7. 7Smoke until the sausages reach about 150–155°F internal, then cool at room temperature or briefly in an ice bath to stop the cooking.
  8. 8Let the sausages dry before refrigerating or vacuum sealing.

Watch it on YouTube

Pitmaster tips

  • Keep everything cold — meat, fat, grinder parts and water. Warm fat smears instead of grinding cleanly, which wrecks the texture and can leave you with dry, crumbly sausage.
  • Weigh your salts on a gram scale. Curing salt especially is used in tiny, precise amounts (2.5 g here) — this is not a place to eyeball.
  • Mix until the meat is genuinely sticky and tacky before stuffing. That protein bind is what gives sausage its firm, snappy bite.
  • Rest the stuffed links uncovered in the fridge overnight to form a pellicle — a slightly tacky surface the smoke clings to. It also gives the cure time to work.
  • Climb the temperature slowly (150 → 200°F over about 6 hours). Rushing it renders the fat and cheese out and can 'fat out' the sausage, leaving it dry.
  • Cool the links in an ice bath or at room temperature right after smoking to set the texture and stop carryover cooking before you refrigerate or vacuum seal.

Storage & reheating

Because they're cured and cooked, these sausages keep well: refrigerate up to a week, or vacuum-seal and freeze up to 3 months. Let them dry fully before sealing.

Reheat gently — a low oven, a warm grill, or a simmer — since they're already cooked through; you're just warming, not cooking. They also freeze and thaw better than most fresh sausage thanks to the cure.

FAQ

Do I have to use curing salt?

For a low, slow smoke like this — where the sausage spends hours in the danger zone — yes. Curing salt (sodium nitrite) protects against botulism and gives the cured colour and tang. Don't confuse it with regular salt, and use the precise weight given.

Why did my cheese melt out of the sausage?

Too much heat, too fast. Use cubes of higher-melt cheese (not shredded), keep everything cold when mixing, and climb the smoker temperature gradually so the cheese softens without running out.

What casings should I use?

Natural hog casings give the classic snap for links this size. Soak and rinse them well before stuffing. Collagen casings work too but don't have quite the same bite.

How do I know the sausage is done?

Cook to an internal temperature of about 150–155°F. Going higher risks drying them out and forcing the fat out; a thermometer is the only reliable way to tell.

Know your cook

More information, cause recipe back stories are stupid

No 500-word life story — just the good-to-know stuff on what’s actually in this cook. Here’s the rundown on every real ingredient, health and nutrition wise.

Pork
Pork is a protein-rich meat that's especially high in thiamine (vitamin B1) — more than most other meats — plus B6, niacin, and selenium. Tenderloin and loin are lean; shoulder and belly are richer, so portion the fattier cuts.
Cheese
Cheese is a good source of protein and calcium and pairs naturally with smoke, but it's also high in saturated fat and sodium — a little delivers big flavour, so treat it as a rich accent.
Chili peppers
Chili peppers are low in calories and high in vitamin C and antioxidants, and their heat comes from capsaicin, which may give metabolism a small nudge. Dial the amount to your spice tolerance.
Curing salt
Curing salt (sodium nitrite) is used in tiny, measured amounts to safely cure smoked sausage and give it its colour and tang. It's important for food safety in slow smokes and must be weighed precisely.
Salt
Salt is essential for seasoning and, in brines and cures, for texture and safety — but sodium adds up fast in BBQ. Season with intention and balance salty cooks with fresh sides.
Fresh herbs
Fresh herbs add aroma and flavour with virtually no calories, sodium, or fat, plus a small dose of antioxidants. They're one of the easiest ways to season without reaching for salt.

General nutrition info only, not medical or dietary advice — portions, brands and add-ons change the numbers.

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