Spicy Smoked Chipotle Tuna Melt in a Cast Iron Skillet

Smoked Chipotle Tuna Melt

This smoked chipotle tuna melt transforms the classic sandwich into a BBQ sensation! Prepared on a Traeger grill, it’s filled with crisp, garden-fresh lettuce and a creamy, chipotle-infused tuna patty—easy and delicious!

Why You’ll Love This Recipe

If a classic tuna sandwich and gooey cheese sound like your kind of comfort food, this smoked tuna patty melt is about to become your new favorite! The star of this dish is the perfectly mixed tuna with a blend of creamy condiments, spicy chipotle peppers in adobo sauce, and a splash of tangy lime juice, all coming together for an explosion of flavor.

What Makes This Recipe Work

The secret to achieving deep flavor and perfect texture in this recipe lies in the smoking process. Smoking not only enhances the taste of the tuna but also crisps up the buns while preventing them from becoming soggy, and gently melts the gouda cheese on top.

Ingredients

  • Canned Tuna – Preferably white albacore
  • Mayonnaise
  • Sour Cream
  • Chipotle Peppers in Adobo Sauce
  • Garlic Salt
  • Lime Juice
  • Smoked Gouda
  • Buns
  • Lettuce
  • Other Sandwich Toppings of Choice

Variations

If tuna isn’t your thing, you can easily swap in shredded chicken. For cheese lovers, feel free to experiment with Swiss, cheddar, or any smoked variety. If you’re in the mood for something tangier, blue cheese could elevate the flavor profile. Always choose high-quality, thick buns to prevent any sogginess in the final sandwich.

Instructions

  1. Prepare the Sauce:

    In a blender or food processor, combine your sauce ingredients until they are creamy and smooth.

  2. Mix the Tuna:

    Flake the drained tuna into a mixing bowl and add the sauce. Stir well to combine, then divide the mixture evenly across four buns.

  3. Set Up for Smoking:

    Place the bottom halves of the buns on a baking tray suitable for smoking. This helps with easy cleanup later.

  4. Top and Smoke:

    Sprinkle the smoked gouda (or your cheese of choice) onto the tuna mixture. Smoke the assembled sandwiches along with the tops of the buns for about 30 minutes at 225°F (107°C). Watch as the tuna changes color and forms a slight crust while the cheese softens beautifully.

  5. Finish and Serve:

    Add your favorite toppings to the sandwiches, put on the bun tops, and enjoy!

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Equipment

  • Smoker Grill
  • Blender or Food Processor
  • Smoker-Friendly Foil Sheet Pan
  • Mixing Bowl
  • Rubber Spatula
  • Knife for cutting buns and/or cheese

FAQs

What Tuna is best?

You can choose between tuna canned in water or olive oil based on your preference. Personally, I recommend tuna in water since it’s drained anyway, saving you the hassle of squeezing out oil.

What to look for when selecting tuna?

Canned light tuna is typically lower in mercury, so I recommend looking for brands labeled “wild caught” for the best quality.

Why is it called a tuna melt?

The combination of hot melted cheese and tender bread creates a gooey texture that pairs perfectly with the crunch of fresh lettuce, making it a delightful “melt.”

Can you eat a tuna melt cold?

Absolutely! However, be aware that the melted cheese might not have the same texture when served cold, which some people may not enjoy.

How should I store leftovers?

If you’re preparing some sandwiches in advance, mix the tuna and condiments beforehand and store them in an airtight container. For leftovers, wrap them in foil and refrigerate, but don’t forget to replace the lettuce when reheating to maintain freshness!

Serve With

  • Chips
  • Salad
  • French Fries
  • Pasta Salad
  • Potato Salad
  • Anything you would enjoy at a BBQ!

If you enjoyed this recipe, please take a moment to leave a ⭐⭐⭐⭐⭐ rating!

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