Roasted Green Chile Sausage

Method

1. Chill everything: Grinder parts, bowl, meat — all should be near-frozen. Warm fat smears instead of cutting cleanly, ruining the texture.

2. Grind: Pass pork and fatback through medium die into a chilled bowl set over ice.

3. Mix: Add chiles, garlic, spices, and ice water. Mix with your hands or paddle attachment until the mixture is tacky and binds to itself when pressed (this develops myosin — the protein that gives sausage its snap).

4. Test: Pinch off a small piece, flatten into a patty, cook in a skillet. Taste and adjust seasoning. This step is non-negotiable — you can't fix seasoning after stuffing.

5. Stuff (if using casings): Thread soaked casing onto stuffer nozzle. Fill evenly, avoiding air pockets. Twist into 5–6" links, alternating direction.

6. Cook: Grill, pan-fry, or roast at 375°F until internal temp reaches 160°F. Rest 5 min.

Equipment

• Meat grinder with medium (3/8") die Recommended: Cuisinart Meat Grinder Attachment · Also good: LEM Manual Meat Grinder
• Sausage stuffer attachment (or stuff by hand with a funnel)

Chef Notes

• The most important thing: Pull at 140°F internal — it carries over to 145°F during rest. The old 160°F rule is outdated and produces dry pork.
• Clean and oil the grates before cooking. A dirty grate causes sticking. Use a paper towel dipped in oil, held with tongs.
• The hands-on time is much shorter than the total time. Most of the 2+ hours is unattended cooking — use that time for sides or cleanup.
• This recipe improves overnight as the flavors meld. Make it a day ahead if you can — it's even better reheated.
• Taste as you go and adjust seasoning at the end. Salt levels change as liquids reduce and flavors concentrate.

Common Substitutions

Ingredient	Substitution	Notes
Pork	Chicken thighs or turkey	Both are leaner — add oil for moisture.
Sausage	Ground meat with same seasonings	Season ground pork to match the sausage style.
Grill	Cast iron skillet + broiler	Sear in skillet, finish under broiler for char.

What You're Learning

• Temperature control in sausage making: cold = clean grind, warm = smeared fat
• Myosin development: mixing until tacky creates the characteristic sausage "bind"
• Always cook a test patty — professional charcutiers do this every time
• Casing technique: even filling, no air pockets, consistent links
• This is charcuterie at its most accessible — homemade sausage is transformative

Foundations Referenced

• → Spice Blends (custom blend below)
• → Techniques — mise en place

What You're Practicing

Grilling over live fire teaches heat management — creating zones of direct and indirect heat, reading the fire, and knowing when to move food. These skills apply to any outdoor cooking method, from charcoal to wood-fired. Visit Techniques for more on fire and heat control.

Roasting uses dry, surrounding heat to caramelize surfaces while gently cooking interiors. The key variables are temperature (high for crust, moderate for even cooking), air circulation (don't crowd the pan), and timing (use a thermometer, not a clock). Visit Techniques for more on oven methods.