Saucy Rossy BBQ
Beef

Leftover Brisket and Italian Sausage Burgers

Leftover smoked brisket, diced and mixed into Sobeys Italian sausage meat, pressed into patties and cooked in cast iron on a Camp Chef stove, with a 3-2-1 burger sauce.

Time~30 min Prep15 min YieldMakes 3–4 burgers CategoryBeef Watch5:33
Leftover Brisket and Italian Sausage Burgers — watch on YouTube

Watch the full cook on YouTube

Method

  1. 1Dice the leftover smoked brisket into small pieces.Small pieces mix evenly through the sausage and hold together in a patty. Big chunks leave weak spots where the patty breaks apart. Keep the fat, because it renders again in the pan and keeps the burger juicy. Cold brisket straight from the fridge is firmer and dices more cleanly.
  2. 2Slit the Italian sausages, peel off the casings and put the sausage meat in a bowl.Two sausages on their own would not have made enough patties, which is why the brisket goes in. Run a knife lengthwise down each casing and it peels away easily. The raw sausage meat is the binder. Its fat and the sticky proteins that salt draws out of it are what hold the brisket together.
  3. 3Mix the diced brisket into the sausage meat and form patties.Mix only until the brisket is evenly spread, because overworking makes a dense, springy burger. Make the patties an even thickness so they cook at the same rate, and press a shallow dimple into the centre to stop them doming. No extra seasoning went in, since the Italian sausage and the brisket were both already seasoned, and that was plenty.
  4. 4Make the burger sauce with 3 parts mayonnaise, 2 parts ketchup and 1 part mustard, mix it well and set it aside in the fridge.It is about the most basic burger sauce there is, and it works. Chilling it while the burgers cook firms it up slightly and keeps it cold against the hot patty. You can add salt, pepper or a spoonful of BBQ rub, but it is good plain.
  5. 5Heat the Lodge cast iron pan on the Camp Chef Pro 14 over medium-low for 2–3 minutes.Medium-low matters here. Brisket bark and seasoned sausage can scorch quickly, and cast iron holds a lot of heat once it is going. The patties should sizzle as they hit the pan. If they do not, give it another minute.
  6. 6Cook the patties, flipping regularly and watching the heat so they brown without burning.Flipping often evens out the cook and stops one side charring before the centre is done. A little crispy char on the outside is fine, but black is not. The brisket is already cooked, but the sausage meat is raw pork, so cook the patties to 160°F in the centre.
  7. 7Spread the burger sauce generously on the bun and add the patty.Putting the sauce on the bun instead of the patty keeps it from sliding off. This is where cheese would go. There was none on hand for the video, but a slice melted on the patty for the last minute in the pan would suit it.
  8. 8Top with tomato, onion and lettuce and close the burger.Cool, fresh toppings balance a rich, fatty patty. Put the lettuce against the top bun so the tomato juice does not soak straight into the bread.

Watch it on YouTube

What each ingredient is doing

Leftover smoked brisket
This was brisket from a competition cook smoked for 12–13 hours, but any leftover smoked brisket works. Point meat has more fat and makes a juicier patty. Lean flat benefits most from the fat in the sausage.
Italian sausage
Raw pork sausage with the casings removed. It brings fat, salt and seasoning. Most importantly, it binds the diced brisket into a patty. Mild or hot both work, and seasoned ground pork is the closest substitute.
Mayonnaise
The base of the sauce. Its fat carries flavour and gives the sauce body.
Ketchup
Sweetness, tang and colour. Using two parts to three of mayonnaise keeps the sauce rich instead of sweet.
Mustard
Sharpness to cut through the fat. One part is enough. Yellow mustard gives the classic burger flavour, and Dijon makes it sharper.
Sesame seed buns
Soft enough to press down around a thick patty. Toast the cut sides in the pan for a minute so the sauce does not soak straight in.

Temperature guide

StageTempWhat it means
PanMedium-lowPreheated for 2–3 minutes. Hot enough to sizzle, not hot enough to scorch.
Safe160°F / 71°CNeeded because of the raw sausage meat. The brisket is already cooked.
CrustBrowned, some charA little crispy char is fine. Black means the heat is too high.
Rest2–3 minutesLets the juices settle before you build the burger.

Pitmaster tips

  • Dice the brisket small. Small pieces mix in and hold together, while big chunks break the patty apart.
  • Keep the brisket fat. It renders again in the pan and keeps the patty juicy.
  • Hold off on extra seasoning. Italian sausage and brisket bark are both already salted, which is why these burgers were left plain.
  • Do not overmix. Stop as soon as the brisket is evenly spread through the sausage meat.
  • Make the sauce first and chill it. It is better cold against a hot burger.
  • Keep the heat at medium-low. Cast iron holds heat, and brisket bark can scorch before the pork in the centre is cooked.
  • Flip regularly and stay with the pan, because keeping the patties from burning is the only real job during the cook.
  • Make sure the centre reaches 160°F. The brisket is already cooked, but the sausage is raw pork.
  • Toast the buns in the pan after the patties come out. The rendered fat crisps them up.
  • Press a small dimple into each patty before cooking so it stays flat.

If it goes wrong

The patties fell apart
The brisket pieces were too large, or there was not enough sausage to bind them. Dice smaller, keep the mix sausage-heavy, and chill the patties for 15 minutes before cooking so they firm up.
Burnt outside, raw centre
The pan was too hot. Use medium-low heat and flip regularly. If the outside is done first, turn the heat down and cover the pan for a minute or two.
The burgers are too salty
Brisket bark and sausage are both salted. Add nothing to the mix, and trim off the heaviest bark if your brisket rub was salty.
The burgers are dry
Lean brisket flat with the fat trimmed off, or the patties went well past 160°F. Keep the brisket fat in, add some point meat if you have it, and pull the patties once they reach temperature.
The patties domed up
Press a thumb-sized dimple into the centre of each patty before it goes into the pan.

Ways to change it up

Cheeseburger
Melt a slice of cheddar or provolone on each patty in the last minute in the pan. It was only left out of the video because there was no cheese on hand.
Hot sauce in the mix
Work a splash of hot sauce into the meat before forming the patties, as suggested in the video.
Extra seasoning
Dust the patties with a BBQ rub before cooking, or stir a little rub into the burger sauce.
On the grill
Set the cast iron pan on a charcoal or gas grill. The diced brisket makes these patties looser than an all-beef burger, so a pan is safer than cooking them straight on the grate.
Hot Italian sausage
Use hot Italian sausage for a spicier burger with no other changes.

What to serve it with

  • On sesame seed buns with the 3-2-1 burger sauce, lettuce, tomato and onion, as in the video.
  • Fries or potato wedges.
  • Coleslaw or a crisp green salad.
  • Pickles on the side to cut the richness.
  • A cold beer.

Storage & reheating

Cooked patties keep 3–4 days in the fridge. The brisket has already been cooked once, so eat them sooner rather than later. The burger sauce keeps about a week, covered and refrigerated.

Reheat the patties in a covered pan over medium-low with a splash of water, or in a 350°F oven, until hot through to 165°F. The microwave toughens the sausage.

Raw patties freeze for up to 3 months with parchment between them, and cooked patties for 2–3 months. Thaw overnight in the fridge before cooking or reheating.

FAQ

Can you make burgers from leftover brisket?

Yes, but diced cooked brisket will not hold together on its own, because cooking has already set the proteins that bind raw ground meat. Mixing it with raw sausage meat solves that. The sausage binds the patty and the brisket adds smoky, beefy flavour and texture.

Do I need to season brisket and sausage burgers?

Usually not. Italian sausage is already seasoned and salted, and brisket carries its bark and rub. These were left plain and the brisket came through clearly. If you are unsure, fry a small piece of the mix and taste it first.

What is in a simple burger sauce?

This one is 3 parts mayonnaise, 2 parts ketchup and 1 part mustard, mixed and chilled. You can add salt, pepper or a spoonful of BBQ rub, but it is good plain.

What temperature should sausage burgers be cooked to?

160°F in the centre, because Italian sausage is raw ground pork. The brisket is already cooked, so the sausage is what you are cooking for. An instant-read thermometer pushed in through the side of the patty is the reliable check.

What heat should I use for burgers in cast iron?

Medium to medium-low, especially with a mixed patty like this. Cast iron holds heat, and brisket bark and seasoned sausage scorch easily. Preheat for a few minutes so the patties sizzle when they go in, then flip regularly.

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.

Beef
Beef is a complete protein and one of the best food sources of highly absorbable heme iron, zinc, and vitamin B12 — key for energy, immunity, and healthy blood. Fattier BBQ cuts are calorie-dense, so lean trimming and sensible portions keep it balanced.
Onion
Onions are low-calorie aromatics rich in fibre, vitamin C, and antioxidants such as quercetin. They add depth and gentle sweetness without much fat or salt.
Tomato
Tomatoes bring bright acidity plus vitamin C and lycopene, an antioxidant that becomes more available when cooked. They lighten and balance rich, fatty barbecue.

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

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