The Ultimate Smoked Bacon Roll

For every true bacon aficionado, the mention of a “Bacon Explosion” is enough to ignite a fire of culinary excitement. This legendary dish is a glorious celebration of pork, masterfully combining ground pork, savory sausage, and an abundance of crispy bacon, all rolled into an irresistible, smoky log of deliciousness. Whether you’re a seasoned pitmaster or a weekend grilling enthusiast, this recipe promises a flavor adventure that’s simple to achieve and incredibly rewarding. You have the flexibility to cook it on a state-of-the-art pellet grill, a classic smoker, or even over indirect heat on a charcoal or gas grill. Regardless of your chosen method, the result is consistently superb – a moist, flavorful, and utterly satisfying centerpiece for any meal or gathering.

If the concept of a “bacon fatty” is new to you, imagine the most succulent meatloaf you’ve ever tasted, but elevated to an entirely new dimension. This isn’t just any meatloaf; it’s a gourmet marvel that is both generously stuffed with crumbled bacon and elegantly encased in a meticulously crafted bacon weave. Each bite delivers a harmonious blend of smoky notes, rich BBQ sauce undertones, and the undeniable savory crunch of bacon that your taste buds will crave. It’s a dish that embodies the spirit of comfort food with an adventurous twist.

Our family has been indulging in Bacon Explosions for years, a tradition that began with my brother, K.C., who has been perfecting this craft for over a decade. His culinary prowess even led him to win a cookoff with his innovative turkey bacon explosion, proving the versatility of this concept. However, this classic pork version remains our undeniable favorite, the original recipe that captured our hearts and stomachs. We first shared this cherished recipe back in May of 2015, a testament to its enduring appeal.

Now, with the convenience and precision of a pellet smoker in our arsenal, it felt like the perfect opportunity to tackle this iconic recipe myself. The experience was incredibly rewarding, and the resulting Bacon Explosion was every bit as delicious as I remembered. The ease of temperature control and consistent smoke infusion truly makes a pellet grill an ideal tool for this kind of low-and-slow cooking, ensuring a perfectly smoked, tender, and juicy result every time.

Essential Ingredients for Your Bacon Explosion

Creating a truly magnificent Bacon Explosion starts with selecting high-quality ingredients. Each component plays a vital role in building the layers of flavor that make this dish so extraordinary.

The Stars: Bacon, Ground Pork, and Sausage

• Bacon (2 pounds, divided): This recipe calls for two pounds of bacon, separated for different uses. One pound will be cooked crispy and crumbled for the flavorful filling, providing a burst of salty, crunchy texture within the meat roll. The other pound is dedicated to crafting the iconic bacon weave, which encases the entire explosion, adding visual appeal and an extra layer of savory goodness. Choose a good quality, regular-cut bacon for the weave; thick-cut can be harder to manage.
• Ground Pork (1 pound): The foundation of our meat core, ground pork offers a rich, mild flavor that pairs beautifully with the sausage and bacon. It contributes to the succulent texture of the finished product.
• Bulk Pork Sausage (1 pound): Adding bulk pork sausage introduces a depth of seasoning and a bit more fat, enhancing the overall juiciness and flavor profile of the meat mixture. A mild or hot variety can be chosen based on your preference for a subtle kick.

The Flavor Boosters: BBQ Rub and Sauce

• BBQ Rub (1-2 Tablespoons): A good BBQ rub is crucial for injecting layers of flavor into both the bacon weave and the meat mixture. It typically contains a blend of salt, sugar, paprika, garlic powder, onion powder, and other spices. You can use your favorite store-bought rub or even a homemade blend to customize the taste.
• BBQ Sauce (1-2 cups): BBQ sauce serves multiple purposes here: a light drizzle within the roll adds moisture and tang, and a final glaze creates a beautiful, caramelized crust and seals in the smoky flavors. The choice of BBQ sauce can dramatically influence the final taste, so pick one you truly love. We often recommend a good quality, slightly sweet and tangy sauce for optimal results.

Step-by-Step Guide to Crafting Your Bacon Explosion

The process of assembling a Bacon Explosion is an enjoyable culinary adventure. Follow these detailed steps to ensure a perfect, mouth-watering result.

Perfecting Your Crispy Bacon Filling

Begin by preparing the bacon for the inner filling. I prefer to cook bacon in the oven because it’s a much cleaner method and allows you to multitask, moving onto the next steps while the bacon crisps up. To achieve perfectly crispy oven bacon:

1. Preheat your oven to 400°F (200°C). Lay out one pound of bacon strips in a single layer on a large, rimmed baking sheet.
2. Place the baking sheet with the bacon into the cold oven, then close the door. Set a timer for 18 minutes. Starting from a cold oven allows the bacon to render its fat slowly and cook more evenly, preventing burning.
3. After 18 minutes, check the bacon. If you prefer it crispier, add a few more minutes to the cooking time, monitoring closely to prevent overcooking.
4. Once cooked to your desired crispness, carefully transfer the bacon strips to a plate lined with paper towels to drain excess grease. Once cooled, crumble the bacon into small pieces and set aside. This crispy texture will be a delightful surprise inside your explosion.

Mastering the Bacon Weave Technique

The bacon weave is not just for aesthetics; it provides a structural wrap that holds the entire Bacon Explosion together and adds an incredible layer of flavor and texture. It might sound intricate, but it’s quite straightforward once you get the hang of it:

1. Lay out a piece of wax paper or parchment paper on a clean, flat surface. This will prevent sticking and make rolling easier.
2. Arrange about half of the remaining pound of bacon strips side-by-side, parallel to each other. These will form the foundation of your weave.
3. Now, gently fold back every other piece of bacon approximately halfway.
4. Place a new strip of bacon perpendicular to the laid-out strips, across the unfolded pieces. Then, fold the previously pulled-back strips over this new piece.
5. Next, take the strips that are now *under* the newly placed bacon strip and fold them back. Lay another perpendicular bacon strip, then fold the original strips back down.
6. Continue this alternating process, adding strips of bacon and weaving them under and over, until you have created a complete, tight weave large enough to encompass your meat mixture (typically about 10-12 inches square). Think of it like weaving a mat.
7. Once your bacon weave is complete, sprinkle a light layer of your chosen BBQ rub evenly over the top. This adds flavor directly to the exterior.

Assembling the Savory Meat Core

With your bacon weave ready, it’s time to prepare the flavorful meat core that forms the heart of your explosion:

1. In a large bowl, thoroughly mix together the pound of ground pork and the pound of bulk pork sausage. Use your hands to ensure the meats are well combined but avoid overmixing, which can make the meat tough.
2. Carefully pat the meat mixture into an even, rectangular layer over the bacon weave. Make sure to leave an approximate one-inch border of exposed bacon weave around all the edges. This border is crucial for properly sealing the roll later.
3. Sprinkle another generous layer of your BBQ rub over the entire surface of the meat.
4. Drizzle a couple of tablespoons of your favorite BBQ sauce over the seasoned meat. This adds moisture and a tangy flavor.
5. Finally, spread the crumbled crispy bacon evenly over the ground meat layer. This ensures that every slice of your Bacon Explosion will have that irresistible crunch.

Rolling It Up: The Art of the Explosion

This is where your Bacon Explosion truly takes shape. The wax paper will be your best friend for this step:

1. Using the wax paper underneath as a guide and support, carefully begin rolling the ground meat mixture from one end into a tight, uniform log. The goal is to form the meat core first.
2. As you roll the meat, the bacon weave will naturally follow. Continue rolling, ensuring the ground pork and sausage mixture forms its own cohesive log.
3. Once the meat log is formed, wrap the bacon weave snugly around it, sealing the ends to create a complete, enclosed “fatty.” Ensure the seam of the bacon weave is on the bottom to help it stay together during cooking.

Smoking and Cooking Your Bacon Fatty to Perfection

The cooking process is crucial for transforming your assembled Bacon Explosion into a tender, juicy, and smoky masterpiece. Here’s how to achieve perfection, no matter your equipment.

Choosing Your Cooking Method

The Bacon Explosion is incredibly versatile and can be cooked using various methods, each imparting its unique character:

• Pellet Smoker: This is our preferred method for its ease of use and consistent results. A pellet smoker, such as a PitBoss XL, excels at maintaining a steady low temperature and infusing food with a consistent smoke flavor without requiring constant attention.
• Traditional Smoker (Charcoal/Wood): For those who love the hands-on experience and deep, authentic smoke flavor, a traditional smoker works wonderfully. The key is to maintain a consistent low temperature (around 225°F) throughout the cooking process. Use wood chunks or chips (hickory, apple, or pecan work well with pork) for flavor.
• Indirect Grilling (Gas or Charcoal Grill): Don’t have a dedicated smoker? No problem! You can easily set up your regular grill for indirect heat. On a gas grill, light burners on one side and place the Bacon Explosion on the unlit side. For a charcoal grill, arrange coals on one side of the grill and place the meat on the opposite side. This prevents direct heat from burning the bacon while allowing it to cook slowly and evenly.

Temperature and Timing Essentials

Precision is key for a perfectly cooked Bacon Explosion:

1. Preheat: Preheat your smoker or grill to a steady 225°F (107°C). Maintaining this low temperature ensures the meat cooks slowly, remaining tender and absorbing maximum smoky flavor.
2. Placement: Carefully transfer the rolled Bacon Explosion to your preheated cooking surface. Place it with the seam of the bacon weave facing down. You can place it directly on the grates or, for easier handling and cleanup, use a perforated grill pan.
3. First Glaze: Cook until the internal temperature of the thickest part of the roll reaches approximately 155-160°F (68-71°C). This is best measured with a reliable meat thermometer. At this point, carefully brush the top and sides of the Bacon Explosion generously with your favorite BBQ sauce. We find that Blues Hog rub and sauce not only tastes fantastic but also creates a beautiful sheen.
4. Final Cook: Continue cooking until the internal temperature reaches a safe 165°F (74°C). The exact cooking time can vary significantly depending on the thickness of your roll, the consistency of your cooker’s temperature, and how often you open the lid. For reference, on our smoker, it typically takes about 1 hour and 45 minutes to reach completion after the initial glaze.
5. Rest and Serve: Once the target temperature is reached, remove the Bacon Explosion from the smoker or grill. Allow it to rest for a few minutes (5-10 minutes is ideal) before slicing. This resting period allows the juices to redistribute, ensuring a moist and tender serving. Slice into 1-inch thick rounds and serve immediately.

Delicious Side Dishes to Complement Your Bacon Explosion

A dish as rich and satisfying as the Bacon Explosion calls for equally delightful side dishes that either complement its robust flavors or offer a refreshing contrast. Here are some fantastic ideas to complete your meal:

• Spring Pea Salad: There’s something truly magical about the combination of warm, rich, smoky meat and a cool, creamy pea salad. The sweetness of the peas and the tang of the dressing provide a perfect counterpoint to the savory Bacon Explosion. It’s a pairing we find ourselves coming back to time and again. Find the recipe here: Pea Salad.

• Oven-Roasted Brussels Sprouts: Brussels sprouts have a natural affinity for bacon. Roasting them brings out their earthy sweetness, creating a caramelized exterior that’s wonderfully tender inside. Serving them alongside the Bacon Explosion allows you to enjoy both flavors without cooking them directly together, offering a balanced and flavorful vegetable option. Get the recipe: Roasted Brussels Sprouts.

• Loaded Jalapeño Cornbread: For a hearty and slightly spicy addition, loaded cornbread is an excellent choice. The sweet and savory notes of cornbread, especially with the kick of jalapeños, pair beautifully with the richness of the pork and bacon. It’s a comforting side that absorbs all the delicious juices. Check out the recipe: Loaded Cornbread.

• Deviled Egg Macaroni Salad: A creamy, tangy macaroni salad with the delightful flavor of deviled eggs offers another superb cool contrast to the warm, smoky main course. Its texture and flavor profile make it a crowd-pleaser and a great accompaniment. Find the recipe here: Deviled Egg Pasta Salad.

If you’re looking to get more use out of your smoker beyond the Bacon Explosion, there are many other fantastic recipes to try. Consider making a smoked turkey breast for a lighter, yet equally flavorful option, or venture into something unique like smoked rabbit on the pellet grill. The possibilities for smoky deliciousness are endless!