Pulled BBQ Chicken Sandwiches

Ingredients

• 25 gbrown sugar
• 7 gsmoked paprika
• 7 gpaprika
• 6 ggarlic powder
• 9 gkosher salt
• 3 gfreshly ground black pepper
• 2bone-in, skin-on split chicken breasts with rib meat
• 4bone-in, skin-on chicken thighs
• to tastehamburger buns
• to tastecoleslaw
• to tastedill pickles, sliced, optional
• to tastelettuce (optional)

Instructions

1. 1

   Season the chicken

   Mix the brown sugar with the spices. Set the chicken pieces on a large, rimmed baking sheet. Gently lift the skin on the breasts and thighs without removing it, rub a generous amount of the spice mix onto the meat, then smooth the skin back into place. Sprinkle the remaining rub underneath the pieces, turn them skin-side up and leave at room temperature while the grill heats.

2. 2

   Preheat the grill

   With the lid closed, preheat the Traeger to 107°C, about 15 minutes. Use Super Smoke if available.

3. 3

   Smoke the chicken

   Insert a leave-in wireless meat thermometer into the thickest part of a breast, avoiding the bone. Smoke the chicken for 1 hour.

4. 4

   Finish cooking

   Raise the heat to 177°C and cook until the chicken is fork-tender. Aim for an internal temperature of 79–82°C in the breasts and 85–88°C in the thighs. This should take about 20 minutes more, though the time depends on the size of the pieces, the weather and the grill.

5. 5

   Shred the meat

   Let the chicken rest until it is cool enough to handle but still very warm. Carefully pour the juices into a fat separator and remove the skin. For quick shredding, put chunks of meat in a stand mixer fitted with the paddle attachment and mix on medium until they reach the texture you like, 30 seconds to 1 minute. Alternatively, shred the meat by hand. Add back some of the reserved juices if you like, and toss.

6. 6

   Build the sandwiches

   Serve the chicken straight away, or portion it, cover it and refrigerate or freeze it. For sandwiches, toss the warm chicken with your preferred BBQ sauce and serve in soft burger buns with slaw, sliced pickles and lettuce if you like.

What is pulled chicken?

Pulled chicken is cooked until tender, then separated into shreds rather than sliced. Like pulled pork, it can be served in a sandwich or used in dishes such as tacos, chilli and nachos.

This version uses a brown sugar and paprika rub, then smokes the chicken before finishing it at a higher temperature. Bone-in pieces bring plenty of flavour, while the thighs and breasts offer a useful mix of meat.

Nutrition and macros by portion

The nutrition label shows one serving as written: 760 calories, 66g protein, 47g carbs, 31g fat.

The chicken supplies most of the protein, while the bun contributes much of the carbohydrate. Fat comes mainly from the chicken thighs and breast, with further variation from the bun, BBQ sauce and slaw. Serve with extra slaw or lettuce for a fresh contrast, and keep any additional sides in mind when building the plate.

Why use bone-in chicken?

Breast and thigh pieces: the breasts give you leaner shreds, while the thighs stay juicy through the longer cook. Keeping the skin on during cooking helps protect the meat; it is removed before shredding.

Getting the seasoning in

Under the skin: lifting it gently lets the rub season the meat directly, while leaving the skin attached protects the surface as it cooks. Smooth the skin back down so it sits close to the meat.

The remaining rub: seasoning the underside as well as the top gives the pieces a more even coating. Letting them stand while the grill heats gives the spices time to settle.

Using two cooking temperatures

Low heat: smoking at 107°C for an hour builds smoky flavour before the faster finishing stage. Keep the lid closed during preheating and cooking as much as possible.

Hotter finish: raising the grill to 177°C helps the chicken reach the specified tenderness and internal temperatures. The stated extra 20 minutes is a guide, so check the meat rather than relying on the clock alone.

Shredding without drying it out

Rest first: wait until the chicken is manageable but still very warm, then remove the skin and separate the meat from the bones. Keep the cooking juices to moisten the shreds if needed.

Mixer or hands: a stand mixer with a paddle makes quick work of chunks in 30 seconds to 1 minute. Check the texture frequently, or use your hands for more control over the size of the shreds.

The sandwich toppings

BBQ sauce: toss it with the warm shredded chicken just before serving so the meat is coated. Add it to taste, since the sauce is not part of the measured spice rub.

Slaw and pickles: creamy or crisp slaw and tangy pickles bring contrast to the soft bun and rich chicken. Lettuce is optional, as are the pickles.

Serving and making extra

Serve the sandwiches while the chicken is warm, with extra slaw on the side if you have it. The shredded meat also works in tacos, burritos, chilli or nachos.

The recipe makes four servings from the listed chicken pieces. If you are cooking ahead, portion the chicken and keep the sauce and sandwich toppings separate until serving.

Recipe notes & tips

• Use a thermometer in the thickest part of a breast and keep the probe clear of bone.
• Pour the cooking juices into a fat separator before returning any to the shredded meat.
• Remove the chicken skin before shredding so the texture stays tender rather than chewy.
• Run the mixer only until the meat is shredded to your liking, checking after 30 seconds.
• Toss the chicken with BBQ sauce just before serving to keep the buns from getting soggy.

Variations

• Skip the smoke: Cook on a suitable grill without Super Smoke if that feature is unavailable.
• Taco filling: Use the shredded chicken in warm tortillas with your preferred toppings.
• Make it saucier: Add more BBQ sauce to the warm chicken a little at a time.
• Leave out the pickles: Serve with slaw and lettuce instead.
• Use the leftovers: Add the chicken to nachos, burritos or chilli.

Common mistakes to avoid

• Pulling off the skin: Lift it gently to season underneath, then smooth it back over the meat.
• Probing near bone: Place the thermometer in the thickest breast meat without touching bone for a useful reading.
• Relying only on the clock: Piece size and grill conditions vary, so check tenderness and internal temperature.
• Overmixing the chicken: Stop as soon as the shreds reach your preferred texture, rather than leaving the mixer running.
• Adding all the juices at once: Toss in a little at a time so the chicken stays moist without becoming wet.

How to store

Keep cooked chicken covered in the fridge for a few days, or freeze it for up to 2 months. Reheat until hot throughout, adding a little reserved juice or BBQ sauce if it needs moisture; assemble the buns and toppings just before serving.

Frequently asked questions