Texas Bowl of Chili Sausage

Follow basic smoked sausage preparation practices when making this sausage.
  1. Clean and sanitize all of your equipment.
  2. Keep your meat and grinder parts super cold (below 34F) at all times
  3. Any liquid that is added to the mince needs to be ice cold
  4. Mix your very chilled meat and seasonings till the mince becomes very tacky
  5. Stuff the mince into sausage casings and prick out any air pockets
  6. Refrigerate your sausage overnight to allow the cure to work
  7. The next day follow a low and slow smoking schedule.
  8. Cook sausages low and slow to an internal of 145f
  9. Once the internal temp has been reached place the sausages in a cold-water bath to cool down and let them bloom at room temperature for 3-4 hours

Here are a few things you might find useful when making a smoked sausage

ThermoWorks Thermapen Mk4

Enjoy the video and the recipe. If you have any questions, feel free to ask away.

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4.60 from 5 votes

Texas Bowl of Chili Sausage

Prep Time1 d 30 mins
Cook Time6 hrs
How much do you want to make? 1000 grams


For the bone broth (if you plan on making it yourself)

  • 1000 g beef bones
  • 6 cloves of garlic
  • 2 bay leaves
  • 113 g onion rough chopped
  • 2 tsp peppercorn

For the Chili Paste

For the Sausage


Prepare the casings

  • Rehydrate your casing the night before you need them. Rinse off the salt and flush the casings with some cool water. Place the cleaned casings in some fresh water with some baking soda in it (I use 1 tsp per quart of water) and place in the refrigerator. If you let your casings soak for at least 12 hours, they will be nice and tender by the time you use them.

Prepare the Bone Broth

  • In a pot add beef bones, the rest of the broth ingredients (garlic, onion, bay leaves, peppercorn) and enough water to cover by an inch. Bring to a simmer and cook for 4-6 hours. Add more water as necessary. Once finished, strain out the broth and set to the side. You want this ingredient to be hot when you use it (you can use store bought bone broth just make sure it's unsalted).

Prepare the Chili Sauce

  • The weight of the peppers in the recipe above is without seeds and stems. So, once you remove the seeds and stems, weigh the dried peppers and place them in a bowl. Add the amount of HOT beef bone broth that the recipe calls for, the roasted garlic, and the spices (including the baking soda) to the dried peppers. If the bone broth is not hot, place it on the stove top and bring to a simmer. This will help rehydrate your peppers better. Cover with cling film and let the peppers rehydrate for 30 minutes.
  • Next blend your pepper mix (everything in the bowl) until you have a smooth paste. Set to the side to cool.

Prepare the Meat

  • Clean meat from any silver skin and arteries. Chill the meat and the fat so that the temperature is below 34f (1.1c)
  • Grind chilled meat and fat on a medium course plate. Rechill. Keep the temp under 34f (1.1c)
  • Combine the rest of the ingredients (spices, binder, chili paste) and mix till the meat turns into a sticky batter. The meat mixture will stick to your hand when you grab a small handful of it and turn your hand upside down.
  • Stuff mixture in your casings and link them to your desired size. If you notice any air pockets, be sure to prick them out
  • Place the sausage in your refrigerator overnight so that the cure can do its job
  • The next day, smoke the sausage using incremental adjustments in temperature to slowly bring the sausage up to a core temperature of 145F (62.7c).

If you have a digital smoker this is a great cooking schedule:

  • 1.5 hours at 100f (37.7c) – this dries out the sausage (leave the dampers wide open)
  • 1.5 hours at 125f (51.6c) – this is when I start applying smoke
  • 1 hour at 155f (68.3c)
  • 1 hour at 175f (79.4c)
  • then I bump up to 200f (93.3c) until I reach an internal of 145f (62.7c)

If you are cooking on a pit or offset here’s a different way:

  • on indirect heat start smoking sausages while the pit is at 150f (65.5c) and smoke for 3 hours.
  • Increase the temperature to 200f (93.3) and cook till you get to an internal of 145f (62.7c)

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6 thoughts on “Texas Bowl of Chili Sausage

  1. Kevin Barteaux
    Kevin Barteaux

    5 stars
    Just finished making a batch. So good! Thank you!

    1. Eric

      Glad you liked it!!! I’m making more this weekend!

  2. MIke

    4 stars
    I tried it this weekend and it tastes fantastic but unfortunately the casing is too chewy. I followed steps to keep water cold but not ice cold and left only to cool for about 5 min. 28mm/30mm casings. But very tasty. Trying it again tomorrow with yellow mustard and white onions for lunch.

    FYI, I don’t know if this was a mistake on my part but I ended up with a lot of left over paste.

    1. Eric

      How long did oyu allow the casings to hydrate and where did you get the casings? Yes. This recipe will make extra chili paste. I just freeze it for later use or add it to ground beef for some really great chili nachos😉

  3. MIke

    4 stars
    The casing came from The sausage maker. I did rinse casings, applied a little baking powder to the water and then let hydrate for about 3-4 hours in the refrigerator. I know it wasn’t overnight so maybe this is the root cause?
    Update, I’ve noticed some are less chewy than others, but I still think its great. I noticed the chewier ones are a little smaller and shriveled up more than others.

    I wasn’t sure what to do with the extra paste but now I know for next time.

    1. Eric

      There are sections of casings that seem to be a little tougher than others. Overnight soaking certainly helps..

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Jump to Recipe Print Recipe Post Views: 1,234 Follow basic smoked sausage preparation practices when making this sausage. Clean and sanitize all of your equipment. Keep your meat and grinder parts super cold (below 34F) at all times Any liquid that is added to the mince needs to be ice
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