Grilled Italian Sausage Rolls with Aioli and Castelvetrano Relish

These Grilled Italian Sausage Rolls are the ultimate summer sandwich—packed with juicy sausage, vibrant basil aioli, and a tangy Castelvetrano olive relish.

Whether for backyard BBQs or a weeknight grill night, these sausages deliver unforgettable flavor in every bite.

Why You’ll Love This Recipe

Gourmet toppings: Homemade aioli and relish take these over the top.

Juicy and smoky: Grilled sausage cooked to perfection.

Great for entertaining: Impressive yet super easy to make.

Customizable: Use your favorite toppings, buns, or relish style.

Ingredient Highlights

Italian Sausage Links – Choose fresh hot or mild links—both work beautifully on the grill and deliver savory, meaty flavor.

Brioche Hot Dog Rolls –  Buttery, pillowy, and lightly sweet, these rolls elevate every bite.

Lemon Basil Aioli –  A blend of mayo, basil, lemon zest, and garlic—this creamy spread adds herbal brightness and zingy flavor.

Castelvetrano Giardiniera Relish –  A briny, crunchy mix of olives, giardiniera, and capers that brings bold texture and acidity.

Balsamic Glaze –  Optional, but a sweet-tangy drizzle makes each bite pop.

Nonstick Cooking Spray –  Lightly misted on the rolls to toast them perfectly on the grill.

Pro Tips Before You Start

Zone grill setup: Use indirect + direct heat zones for perfect sausage cooking.

Don’t over-process relish: Pulse just 3–5 times for a chunky texture.

Prep ahead: Make aioli and relish in advance to save time.

Toast rolls last: Just a quick minute on the grill keeps them crisp, not dry.

How to Make Grilled Italian Sausage Rolls

Step 1: Preheat the Grill
Set up your grill with a zone for direct heat and one for indirect.

Preheat for 15–30 minutes depending on gas or charcoal.

Step 2: Make the Lemon Basil Aioli
Blend mayo, basil, lemon zest, garlic, salt, and pepper in a food processor until smooth.

Transfer to a container and refrigerate.

Step 3: Make the Castelvetrano Relish
In the same food processor, pulse olives, giardiniera, and capers a few times until chunky.

Store in an airtight dish.

Step 4: Grill the Sausage
Place sausages on the indirect heat side of the grill, close the lid, and cook for 4–5 minutes.

Flip and repeat until they reach 150°F.

Step 5: Chargrill the Sausage
Move sausages to direct heat and grill for 2–3 minutes per side until beautifully charred and the internal temp hits 160°F.

Rest briefly before serving.

Step 6: Toast the Rolls
Spritz brioche rolls with nonstick spray and toast over direct heat for about 1 minute until golden and crisp.

Step 7: Assemble and Serve
Add sausage to toasted rolls, top with relish, aioli, and balsamic glaze.

Serve immediately and enjoy!

What to Serve It With

Grilled corn on the cob

Italian pasta salad

Potato chips or kettle crisps

Iced tea, lemonade, or a light beer

Variations & Substitutions

Try different sausage: Bratwurst, chorizo, or chicken sausage.

No basil? Use parsley or arugula in the aioli.

No relish ingredients? Swap for jarred olive tapenade.

Spicy version: Use hot giardiniera and a pinch of chili flakes in the aioli.

Storage & Leftovers

Sausage: Store grilled sausages in the fridge for 3–4 days.

Aioli & relish: Keep in airtight containers—aioli lasts 1 week, relish up to 2 weeks.

Reheat sausage: Use a skillet or oven at 350°F until warmed through.

FAQs

Can I make the aioli and relish ahead of time?
Absolutely! Both store well and taste even better after a day in the fridge.

What’s the best kind of sausage to use?
Fresh Italian sausage—either hot or mild—delivers the best flavor and grill marks.

Can I use a grill pan instead?
Yes, a stovetop grill pan works.

Cook over medium heat and monitor temps closely.

Is there a dairy-free option for the aioli?
Yes! Use a dairy-free mayo as your base.

How do I know when the sausage is fully cooked?
Use an instant-read thermometer—look for 160°F at the thickest part.

Can I bake the sausages instead?
You can! Roast at 375°F for 25–30 minutes, flipping halfway through.

Do I need to toast the buns?
Highly recommended! It adds texture and prevents sogginess.

Final Thoughts

These Grilled Italian Sausage Rolls are everything a great summer meal should be—simple, bold, and bursting with flavor.

The fresh toppings, charred sausage, and golden rolls come together for a meal that’s as satisfying as it is shareable.