The other day the guys from BaconToday.com contacted me in search for some barbecue bacon recipes. Of course I have plenty of great uses for bacon in a barbecue pit, but the longer I thought about it, the more I wanted to step it up a notch and clog a few arteries for those guys. Behold, BACON EXPLOSION!!! Here’s what you’ll need…
Bacon Explosion Ingredients
- 2 pounds thick cut bacon
- 2 pounds Italian sausage
- 1 bottle of Burnt Finger BBQ sauce
- 1 shaker of Burnt Finger BBQ rub
To kick off the construction of this pork medley you’ll need to create a 5×5 bacon weave. If the strips you’re using aren’t as wide as the ones pictured, then you may need to use a few extra slices to fill out the pattern. Just make sure your bacon weave is tight and that you end up with a nice square shape to work with.

The next step is to add some seasoning on top of your bacon weave. I used our Burnt Finger BBQ Smokey Kansas City seasoning (the label artwork has changed since this photo was taken), but many rubs will work. Here are some of my favorites that are available on Amazon.
The key here is to use a seasoning that is more sweet than salty. The bacon is already bringing a good amount of salt to party, so you want to avoid getting your Bacon Explosion over salted.

Now that you’re pork is well seasoned, it’s time to add more pork. Take two pounds of Italian sausage and layer it directly on top of your bacon weave. Be sure to press the sausage to the outer edges of the bacon creating a patty that is the same thickness all the way across. Most grocery stores carry loose sausage, so just pick out one you like. I chose to go with a mild sausage, but spicy would work just the same. If you really want to get crazy, take a stab at making your own homemade sausage.

Next up is bacon layer number two. Take the remaining bacon slices and fry them up the same way you would for breakfast (or lunch, or dinner, or a midnight snack). If you like soft bacon, make it soft. If you like crunchy bacon, make it crunchy. If you like your bacon burnt to hell so the smoke detectors go off, then burn it to hell so the smoke detectors go off. These pieces are going to be a major part of the inner flavor of our sausage fatty, so cook them your favorite way. Personally, I like my bacon right at the point when it starts to get crispy, but hasn’t quite lost all of the softness yet. Regardless of how well done you like yours, you’ll need to crumble or chop the cooked strips into bite size pieces and place on top of the sausage layer. (Note-It’s okay, and encouraged, to snack on these pieces while your chopping/crumbling. But keep in mind that once those bacon morsels touch the raw sausage, you’ll need to resist all temptations to nibble. This can and will be difficult, but hospital trips are no fun, so stay strong.)

Since this is a BBQ recipe, we need to add another layer of BBQ flavor. Take your favorite sauce and drizzle it all over the top of the bacon pieces. I use our Burnt Finger BBQ Smokey Kansas City sauce, but any BBQ sauce that you like will work. Here are some of my favorites that are available on Amazon.
Once you’ve sauced the bacon, sprinkle on some more of the Smokey Kansas City Barbecue Seasoning you used on the bacon weave.

Now comes the fun part. Very carefully separate the front edge of the sausage layer from the bacon weave and begin rolling backwards. You want to include all layers EXCEPT the bacon weave in your roll. Try and keep the sausage as tight as possible and be sure to release any air pockets that may have formed. Once the sausage is fully rolled up, pinch together the seams and ends to seal all of the bacon goodness inside.

At this point we can start to see the final shape of our Bacon Explosion, but we’re missing one key item. To complete the construction process, roll the sausage forward completely wrapping it in the bacon weave. Make sure it sits with the seam facing downward to help keep it all sealed up.

Sprinkle some more Smokey Kansas City Barbecue Seasoning on the outside of the bacon weave, and now this bad boy is ready for the smoker. Cook your Bacon Explosion at 225 degrees in a constant cloud of hickory smoke until the meat reaches an internal temperature of 165 degrees. Normally this will take about 1 hour for each inch of thickness, but that could vary depending on how well you maintain your fire and also how many times you open the smoker to take a peek. Mine took about 2.5 hours, which was right on target with its 2.5 inch diameter.


Now that our Bacon Explosion is fully cooked, we need to add some finishing flavors. Remember that Burnt Finger BBQ sauce we used for inner flavor? We’ll be using that same sauce to glaze the cooked bacon weave. Using a basting brush, coat the entire surface with a thin layer of sauce.

Slice the Bacon Explosion into quarter to half inch rounds to serve. If your roll was good and tight, you should now see a nice bacon pinwheel pattern throughout the sausage. Obviously pork is best served by itself, but if you feel the need to make this meat monster into a sandwich, try placing a couple Bacon Explosion slices on a warm Pillsbury’s Grands Biscuit. You’ll reach pork Nirvana in no time flat!


That right there is all man, only real men can eat that. But really and truly, it is a heart attack in a plate. Only the brave should even attempt to try and eat this.
just had a heart attack watching it
Halleluja! Halleluja!Halleeeelllluuujaaaa!
Skals betaband salutes the mighty heart attack!!
i don’t know whether to eat it or smear it around inside my aorta. i could see whipping one up with, say, a bratwurst stuffed inside and feeding it to a large crowd of carnivores. It would make for a real steatoganza.
I think I’m in love!
Atkins would approve! lol!!
. . . and then add jalapenos and shredded sharp cheddar before you roll up the sausage . . .
Holy Shit! I need to go and take a cold shower
I think i’ll kill myself with that! I think i’ll record a video of everything i did to make that suicide Roll. I’ll let you know when it’s over. It may take a while cause it’s winter and we never use our charcoil in winter. But anyways i’ll try to convince my father to buy every ingredients and i’ll try to make it in the oven, even though i don’t know how to see internal temperature… see ya!
I wish I could quit you, bacon.
Somebody should send a couple of these to Randy Taylor and his family.
http://consumerist.com/consumer/audio/devoted-customer-upset-jimmy-dean-downsized-sausage-16oz-to-12oz-but-charges-same-price-322223.php
I made a Fiery Explosion which included hot sausage, Stubbs spicy bbq sauce, and some mozzarella cheese…. It was/is incredible….
Today (1-19-09) I made the Bacon Explosion. WOW! First of all, the Italian sausage available here (South Texas mid-coast area) was so bland. I used half hot and half regular. It was fun to make but the taste was missing. My guess is, it was the Italian sausage. Next time I’ll use Owens Hot sausage. Makes an impressive presentation though.
Perfect for the Aikin Diet (no carbs if not in rub or sauce). Since I’m now on that diet, there’s a BARBECUE EXPLOSION in the making as I write !
Oh man. It’s so much pork, it has come full circle. It is now a vegetable.
Now all it needs is to be dipped in batter and deep fried.
I would force Muslims to eat this as a form of torture. Too bad they would enjoy it and Convert! PS, SCREW OBAMA
LOL. Not exactly a political statement, but glad you liked it nonetheless!
Ok.. did it was a little tricky to roll but i also did add a bag of shredded cheddar and then slice up two jalepanos and mixed that in the meat. So dont know how the spiral will be but as for the sausage i used hot sausage too! Amazing!!!
I tried your recipe over the weekend and it is AWESOME!
@John Great! if you took pics, send them over, we’re doing a follow up post on everyone else soon.
Instead of BBQ rub, I used Baconsalt (baconsalt.com) and it was DIVINE. Now, if you will excuse me, The ambulance is here to take me to the hospital to clear out my arteries 😉
@kellleyD – The grocery store near my house just started carrying Bacon Salt. I picked up a bottle of it the other day, but haven’t had a chance to use it yet. Next time I whip up a couple Bacon Explosions I’ll put it to good use!
I can’t wait to make this!!! We are going to make it for Super Bowl. I have taken the Monday off work just in case I don’t make it. If I do make through the night and the next day I will be talking about it on my morning show, everyone on our show loves bacon as well, they will be so jealous.
Thank you sooooooo much for this! Again, I can’t wait to make it!!
@Ali Great! Let us know how it turns out!
@Ali – Can’t wait to hear your thoughts! I’m sure your listeners will thank you as well. 🙂
After reading all these statements and testimonials I am truly in awe! I believe god made bacon as a sign that he loves us and that it should be wrapped around everything that is edible. I am a member of a motley crew known of as “camp Sausage” We go to bluegrass festivals and eat sausage with every meal (along with most other pork products) I’ve gotten the technique for wrapping bacon around marshmallows down tight… I cannot wait to throw a few of these slabs into the smoke chamber, burn a few fatties, and pass the whiskey ’round!!! The Amish make some wicked bacon and sausage down here in south eastern Pa. I hope they will profit greatly from my efforts to spread the gospel!!!
My arm went numb reading that.
Gonna make at least one of these for Super Bowl
To Laura who commented 12/28/3008 at 8:25 pm. A plant is a living thing, a bacteria is a living thing, a virus is a living thing. You are an idiot.
I am going to make mine with venison sausage just as soon as I can dig my smoker out of the snow. If I have a heart attack after eathing this, so be it. Who wants to live forever? At least I will die with a great big greasy smile on my face.
Ugh..that definitely looks like….. something lol
Only in America. wow.