Jalapeño Cheddar Smoked Sausage from Scratch

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.

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