Chili Brats Casserole
We wanted something hearty, quick, and a little spicy for a chilly evening. After a busy day with friends and kids on the way, this casserole fit the bill. Cooked in our Pacific Living Outdoor Oven, it stays warm until everyone is ready to eat, and the crunchy tortilla chip topping was a hit. This recipe scales easily—double or triple it when you have guests.
We also enjoy one night a week as date night. Sometimes we cook outside on the patio and sometimes inside, but we always make the meal a little special with good food, a drink, and music. The outdoor oven is convenient when we want to keep things warm and serve right from the cooker.
Chili Brats Casserole
An Outdoor Cooking Recipe
Prep Time: 10 minutes
Cook Time: 400°F (205°C) for 60 minutes
Ingredients: Chili Brat Casserole
- Italian sausage or brats — hot, mild, or a mix
- 2 cans (15 oz each) chili — we used hot without beans
- Shredded Mexican cheese blend
- 4 cups tortilla chips, crushed and divided
Directions: Chili Brat Casserole
Lightly grease a heavy cast-iron Dutch oven. Pour half of the crushed chips into the bottom to form a base. Arrange the sausages on top of the chips. Pour the chili over the sausages and then sprinkle the shredded cheese evenly over the chili. Finish by covering the cheese with the remaining crushed tortilla chips.
Lay Sausages on Top of Chips
Sprinkle Cheese on Top of Chili
Ready for the Outdoor Oven
Cooking Directions
Preheat your outdoor oven to 400°F (205°C). If using a smoke box, add wood chips or pellets for added flavor. Place the Dutch oven on the middle rack if possible to avoid excessive direct heat from the bottom stone. Cook for about 60 minutes, checking toward the end to ensure the chip topping is golden and the cheese has melted.
Note: The bottom stone in many outdoor ovens gets very hot. Use heavy cast iron or ovenproof baking dishes and consider the middle shelf for even cooking. Adjust time and temperature as needed for your specific oven.
Let’s Eat!
About Our Recipes
We test recipes outdoors on a variety of grills and smokers, from pellet grills to wood smokers and conventional gas units. Our approach focuses on straightforward, family-friendly meals that translate across different cooking platforms. The key is time and temperature—those two elements will make or break a dish, whether you cook on a pellet grill, gas, wood, or charcoal.
A recipe is a guideline, not a rule. Feel free to adapt ingredients and techniques to suit your taste and equipment. Cooking outdoors adds flavor, but these recipes can often be adapted for the oven or slow cooker when needed.
Live your passion,
Ken & Patti
Our Thanks To:
Country Bob’s All Purpose Sauce
Maverick Industries, Inc.
F. Dick Professional Knives and Tools
PelletCan — storage container & dispenser for wood pellets
Lodge Cast Iron
Lumberjack Wood Pellets
Pacific Living Outdoor Oven