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chicken sandwich on wooden board surrounded by potato wedges and dip

The ULTIMATE Grilled Chicken Sandwich

Juicy chicken thighs, topped with the most delicious sandwich fillings all stuffed between crisp Brioche buns!
5 from 2 votes
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Course: Dinner
Cuisine: American
Prep Time: 15 minutes
Cook Time: 15 minutes
Total Time: 30 minutes
Servings (click & slide): 4 sandwiches
Calories per serving: 592kcal
Author: Chris
Cost per serving: £3 / $4


  • Rolling Pin/Mallet & Cling Film (for pounding chicken)
  • Griddle Pan & Tongs (or cast iron skillet/regular frying pan)
  • Large Shallow Bowl or Zip Lock Bag (for marinating)
  • Sharp Knife & Chopping Board



  • 4x 5oz / 150g boneless/skinless Chicken Thighs
  • 1.5 tbsp Olive Oil
  • 1 tbsp Lime Juice
  • 1.5 tsp Smoked Paprika
  • 1/2 tsp EACH: Salt, Onion Powder, Garlic Powder
  • 1/4 tsp EACH: Cayenne Pepper, Black Pepper


  • 4 Brioche Buns, toasted (see notes)
  • 8 slices of Bacon, cooked to preference
  • 4 tbsp Chipotle Mayo
  • 4 Lettuce Leaves
  • 3 Tomatoes, sliced (3 slices per sandwich)
  • Crispy Fried Onions to preference


  • Pound Chicken: Lay a chicken thigh on your chopping board and cover with cling film (pinch around edges so no moisture escapes). Use a rolling pin or mallet to pound until even thickness, but not so thin it starts breaking apart. Repeat with remaining thighs.
  • Marinade: In a shallow bowl or the base of a zip lock bag, use a fork to whisk together smoked paprika, onion powder, garlic powder, salt, black pepper, cayenne pepper, lime juice and olive oil. Add in chicken thighs and combine until they're all completely covered with the marinade. Marinate for as long as you have time for (up to overnight). If you're in a rush just rest at room temp as you prep the other ingredients.
  • Grill Chicken: Bring chicken to room temp if marinated in the fridge, then add to a griddle pan over medium high heat. Fry until it begins to char (4-5mins), then flip and continue frying until charred on the second side and piping hot through the centre. Place to one side to rest.
  • Sandwich: Stack the sandwich in the following order - bottom bun, chipotle mayo, lettuce, tomato, bacon, chicken, crispy onions, top bun with more chipotle mayo spread on it. Enjoy!

Quick Demo


a) Can I use Chicken Breast? - Yep! Just make sure it's boneless/skinless and around the same weight (5oz/150g per breast). Same method apart from that. They will cook slightly quicker than thigh.
b) Crispy Fried Onions - You can buy these at the store or make your own. You could even use onion rings if you fancied!
c) Marinating - Longer the better, but even just 15mins will work wonders. In all cases though just make sure you bring the chicken close to room temp before frying. If you fry cold chicken it'll seize up and go chewy.
d) Brioche Buns - I like using brioche buns because the sweetness balances out the spice of the chicken/chipotle mayo. You can use other burger buns if you wish! To toast them just place in a dry scorching hot pan until lightly charred, or place under the grill and broil.
e) Calories - per sandwich without the fried onions:

Your Private Notes:

Nutrition Facts
The ULTIMATE Grilled Chicken Sandwich
Amount Per Serving
Calories 592 Calories from Fat 290
% Daily Value*
Fat 32.21g50%
Saturated Fat 7.143g45%
Trans Fat 0.067g
Polyunsaturated Fat 10.108g
Monounsaturated Fat 12.417g
Cholesterol 205mg68%
Sodium 1131mg49%
Potassium 783mg22%
Carbohydrates 24.36g8%
Fiber 2g8%
Sugar 4.29g5%
Protein 48.78g98%
Vitamin A 1431IU29%
Vitamin C 8.7mg11%
Calcium 102mg10%
Iron 3.81mg21%
* Percent Daily Values are based on a 2000 calorie diet.
*Nutrition is based on the absence of salt unless stated as a measurement in the ingredients. Cost is worked out based on ingredients bought from UK supermarkets, then divided by the number of servings. In both instances these values are just for guidance. Please check out my FAQ Page for more info.
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