The Ultimate Smoked Italian Fatty

Imagine all the bold, zesty flavors of a classic Italian sub wrapped in savory sausage and a crispy, smoky bacon weave. This Smoked Italian Fatty is a true BBQ showstopper, packed with premium deli meats and melty cheese for an indulgent taste sensation like no other.

🥓 The Ingredients

This recipe brings together a savory blend of premium deli meats, melty cheeses, and zesty Mediterranean accents, all perfectly encased in a seasoned sausage and bacon shell. Find ingredient notes (including substitutions and variations) below.

📝 Ingredient Notes and Substitutions

• Italian Sausage: You can use mild, sweet, or hot Italian sausage depending on your heat preference; if you can’t find bulk sausage, simply buy links and squeeze the meat out of the casings.
• Deli Meats: This recipe is highly customizable—feel free to swap the soppressata or mortadella for capicola, prosciutto, or even thin-sliced ham.
• The Cheese: Provolone and mozzarella offer the classic “cheese pull,” but you can substitute them with Muenster or Havarti for a similarly mild, melty result.
• Bacon: Use thin-cut bacon for the weave; thick-cut bacon is harder to wrap tightly and often takes much longer to crisp up in the smoker.
• Peppers: Ensure your pepperoncini and roasted red peppers are well-drained and patted dry with a paper towel to prevent the interior from becoming too watery during the cook.
• BBQ Rub: Look for a savory or “all-purpose” rub rather than a very sweet one; flavors like garlic, onion, and black pepper pair best with the Italian ingredients. Or go with our Easy BBQ Rub!

Refer to the recipe card (with video) below for a full list of ingredients and measurements.

🔥 Tips and Tricks for the Perfect Smoked Fatty

• Master the Plastic Wrap: Don’t skip the plastic wrap! It is the secret to getting a tight, uniform log. Use it to provide tension while rolling to ensure your sausage and bacon are packed firmly so the fatty doesn’t fall apart on the smoker.
• Chill Before the Weave: After rolling the sausage and fillings, let the log chill in the refrigerator for at least 30–60 minutes. A cold, firm roll is much easier to wrap in the bacon weave than one at room temperature.
• Keep the Weave Tight: When creating your bacon weave, make sure the strips are touching or slightly overlapping. A tight weave acts as a secondary seal to keep all that delicious melted cheese inside the meat where it belongs.
• Dry Your Fillings: Pat the roasted peppers and pepperoncini dry with a paper towel before adding them to the sausage. Excess moisture can cause the sausage to steam from the inside, potentially preventing the roll from sealing properly.
• Trust the Temp, Not the Clock: While 90 minutes is a good guideline, every smoker and every “fatty” is different. Use a wireless meat thermometer to pull the meat exactly at 165°F to ensure it is juicy and perfectly cooked.
• The Rest is Best: Resist the urge to slice into it immediately! Let the fatty rest for about 10 minutes after taking it off the heat. This allows the juices to redistribute and the cheese to set slightly so you get clean, beautiful slices.

👩🏼‍🍳 How to Make a Smoked Italian Fatty

1. Step 1: On a sheet of plastic wrap, spread the Italian sausage to create a 10″x12″ rectangle.

2. Step 2: Leaving about an inch of space around the edges of the sausage, add single layers of the provolone, pepperoni, salami, and soppressata.

3. Step 3: Top that with pepperoncini, roasted peppers, mozzarella, oil, vinegar, and a sprinkle of dried oregano.

4. Step 4: Gently bring the sides of the sausage together to form a seal. Tighten the ends of the plastic to form a tight log. Place in the fridge (watch the video for visual guidance).

5. Step 5: On another sheet of plastic wrap, weave the bacon into an 11″x13″ rectangle (watch the video for visual guidance).

6. Step 6: Remove the sausage roll from the plastic wrap and place it on the bacon weave. Use the plastic wrap under the weave to help you encase it around the sausage roll.

7. Step 7: Remove the plastic wrap, sprinkle the fatty all over with BBQ rub. Smoke for 90 minutes at 225°F, or until an internal temperature of 165°F is reached.

8. Step 8: To crisp the bacon, place the fatty under the broiler for a minute or two. Let rest for a few minutes, then slice and serve!

🍽️ How to Serve

• Slice into Medallions: Use a sharp serrated knife to cut the fatty into 1-inch thick rounds; this showcases the beautiful spiral of meat and melted cheese inside.
• The “Sub” Experience: Even though this is a breadless masterpiece, you can serve the slices on toasted ciabatta or a hoagie roll with a little extra mayo or pesto if you want to turn it back into a traditional sandwich.
• Dipping Sauces: Serve with a side of warm marinara sauce for dipping, or drizzle the slices with a balsamic glaze to cut through the richness of the bacon and sausage.
• Perfect Side Pairings: Balance out the hearty, smoky flavors with a crisp Caesar salad, a light pasta salad, or some grilled veggies.
• Garnish for Impact: Sprinkle the platter with fresh chopped parsley or basil and a dusting of grated Parmesan cheese to give it a professional, “food-blog-ready” finish.
• Platter Style: Arrange the slices overlapping on a wooden cutting board or a large platter to make it the centerpiece of your next game day or backyard BBQ.

🙋🏽‍♂️ Frequently Asked Questions

💨 More Amazing Smoker Recipes

Ready to make the best smoked “fatty” on the BBQ circuit? Go for it!

And when you do, be sure to take a photo of it, post it on Instagram, and tag @HowToFeedaLoon and hashtag #HowToFeedaLoon!