This post is sponsored by the Missouri Pork Producers Association. All opinions and recipes are my own.
This grilled cheese sandwich is crispy on the outside thanks to a mashed potato crust, melty in the middle with two kinds of cheese, and held together by buttery sourdough bread.
If you made my Pulled Pork on Sourdough Hawaiian Rolls, you've probably got a generous amount of saucy pulled pork in the fridge.
These grilled cheese sandwiches are what I would make on day two, when I want something completely different but still want to put that pulled pork to work.
This recipe is part of my partnership with the Missouri Pork Producers Association, and it's a good example of why I love working with pork.
One pot of pulled pork can turn into many different meals. The bold flavor holds up beautifully through reheating and reinventing, and it's an easy way to feed a family without doing all-new prep every night.
I highly recommend using a sturdy kind of bread for this recipe, rather than sandwich type of bread. Check out my recipe for Classic Sourdough Bread, or my popular recipe for Sourdough Bread Baked in Loaf Pans.
Jump to:
- Why I Love This Recipe for Grilled Cheese and Pulled Pork Sandwich on Sourdough Bread
- Equipment Needed
- Ingredients For Grilled Cheese and Pulled Pork Sandwich on Sourdough Bread
- Key Steps To Make Grilled Cheese and Pulled Pork Sandwich on Sourdough Bread
- Recommended Substitutions
- Storage
- Make Ahead Instructions
- Frequently Asked Questions
- Crispy and Melty Grilled Cheese and Pulled Pork Sandwich on Sourdough Bread
- Related Recipes
- subscribe to get my recipes
Why I Love This Recipe for Grilled Cheese and Pulled Pork Sandwich on Sourdough Bread
- The mashed potato crust is the magic. You spread a thin layer of mashed potatoes on the outside of the sandwich and pan-fry it in olive oil and butter. As it cooks, the potatoes form a golden, shatteringly crispy shell around the bread.
- Inside, you've got muenster and mozzarella melting around saucy pulled pork on garlic herb buttered sourdough. Come on! That sounds amazing, right? Muenster brings a creamy note. Mozzarella adds the long stretchy pull. The pulled pork is already loaded with flavor from its braise, so all the sandwich has to do is hold it together.
- The medium heat is non-negotiable. Most grilled cheese recipes tell you to go low and slow, but the potato crust needs real heat to crisp up. Don't be afraid of heating up the pan.
Equipment Needed
You don't need anything fancy, but a few specific tools make this much easier.
- Small saucepan to boil the potatoes in
- Potato masher or fork
- Small bowl for the garlic herb butter
- Microplane or fine grater for the garlic
- Cast iron skillet, the bigger the better. I love my forever fateful 12" skillet.
- Large spatula for flipping
- Butter knife or small offset spatula for spreading
Ingredients For Grilled Cheese and Pulled Pork Sandwich on Sourdough Bread
Here's what each ingredient does and why it's in the recipe.
- Sourdough bread has the structure to hold up to the mashed potato exterior, juicy pork and melty cheese, without getting soggy. The slight tang also balances the richness of everything else.
- Pulled pork is the saucy, smoky filling that makes this sandwich more than just grilled cheese.
- Muenster cheese is a soft, mild melter with a creamy edge.
- Mozzarella cheese brings that classic stretchy pull. Use low-moisture mozzarella for the best melt, fresh mozzarella will release too much water.
- Unsalted butter shows up three times in this recipe (in the herb butter, in the mashed potatoes, and in the pan), which sounds like a lot but each time it plays a different role.
- Garlic grated on a microplane melts into the butter and spreads evenly across the bread.
- Fresh parsley brightens the garlic butter and adds flecks of green that you'll see when you bite in.
- Russet potatoes are the right pick for the mashed potatoes on the crust. They're starchy enough to mash smooth and crisp up beautifully when pan-fried. Yukon golds will work but won't get quite as crispy.
- Whole milk loosens the mashed potatoes just enough to make them spreadable.
- Olive oil in the pan gives you the high smoke point needed for the extended grilling time, combined perfectly with the flavor and browning of the butter.
See recipe card for quantities.
Key Steps To Make Grilled Cheese and Pulled Pork Sandwich on Sourdough Bread
The recipe card has the full breakdown but here's what to focus on.
Boil the potatoes until truly fork-tender. Undercooked potatoes will be lumpy and won't spread evenly on the sandwich.
Mash and season the potatoes while they're still warm. They absorb butter and salt better that way and stay smooth.
Make the garlic herb butter while the potatoes cool. Melted butter, grated garlic, parsley, salt. That's it.
Spread the garlic butter on all four slices. This is the inside of the sandwich. Don't skip the herb butter, it's what takes this from good to memorable.
Layer the cheese, then pork, then more cheese. This way both cheeses melt against the bread and the pork, creating a sealed pocket of melty goodness.
Spread mashed potatoes on the outside of the sandwich. Edge to edge, pressed into all the nooks and crannies of the bread.
Cook on medium heat with olive oil and butter. Medium, not low. The potato crust needs the heat to crisp.
Don't move the sandwich while it cooks. Just let it sit and develop a deep golden crust.
Spread potatoes on the second side while the first side cooks.
Then flip. The first side will be crispy and ready to support the weight of the still-soft second side.
Rest on a wire rack before slicing. Even one minute helps the cheese set just enough to bite cleanly.
Recommended Substitutions
- Sourdough bread: Although a sturdy bread that slices well (like sourdough or a country loaf) works best, a softer sandwich bread would work as well.
- Muenster: Provolone, havarti, or fontina are all great swaps.
- Mozzarella: Monterey jack, cheddar or American cheese will give you a similar pull.
- Russet potatoes: Yukon gold works in a pinch but the crust won't be quite as crispy. Avoid waxy red potatoes, they're too dense.
- Whole milk: Half and half or even a splash of cream make the mashed potatoes richer. You can use almond milk as well.
- Fresh parsley: Fresh chives or a mix of fresh herbs work great. Dried herbs work great as well.
- Olive oil: Avocado oil or any neutral oil with a high smoke point will work.
Storage
Room temperature: Best eaten fresh. The crispy potato crust loses its texture if it sits too long.
Refrigerator: Store leftover sandwiches in an airtight container for up to 1 day. The crust will soften but the flavors are still great.
Freezer: I don't recommend freezing assembled sandwiches because the potato crust gets gummy when thawed. Freeze the pulled pork separately instead.
Reheating Tips
From the fridge: Reheat in a 375°F (190°C) oven on a wire rack set over a sheet pan for 8 to 10 minutes. The wire rack helps the crust crisp back up. Skip the microwave, it'll make everything soggy.
Make Ahead Instructions
Pulled pork: Make up to 3 days ahead and refrigerate, or up to 3 months ahead and freeze. Thaw and warm gently before assembling.
Mashed potatoes: Can be made up to 1 day ahead. Warm slightly before spreading on the sandwich so they're easier to work with.
Garlic herb butter: Make up to 3 days ahead and store in the fridge. Warm to a spreadable consistency before using.
Frequently Asked Questions
The starch crisps up like a hash brown when it hits hot fat, giving you a crunchy, golden exterior that's totally different from regular grilled cheese. It also adds a soft, savory layer that complements the pulled pork.
You probably need more heat. Bump the burner up to medium and give the sandwich at least 4 minutes without moving it. Also make sure your butter is fully melted and the pan is hot before the sandwich goes in.
The potatoes need to be thick enough to hold their shape. If they're too loose, mash a little more or skip the milk. Press them firmly onto the bread, especially in the nooks and crannies of the crust.
Yes, that's actually a great use for them. Just warm them slightly so they spread easily.
Cover the skillet with a lid for the last minute of cooking. The trapped heat melts the cheese without overcooking the crust.
Pickled jalapeños, caramelized onions, or a smear of barbecue sauce are all great additions. Just don't overload the sandwich or it gets hard to flip.
Mozzarella gives you the stretchy pull, muenster gives you the creamy melt. Together they cover both textures.
You can, but at that point it's just a regular grilled cheese with pulled pork. The potato crust is what makes this recipe special. Try it once before deciding to skip it.
The press will smash the potato crust and you'll lose the crispy texture. Stick with the cast iron pan and a confident flip.
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Crispy and Melty Grilled Cheese and Pulled Pork Sandwich on Sourdough Bread
Ingredients
For the pulled pork
- Use the pulled pork recipe from my Sourdough Hawaiian Roll Pulled Pork Sandwiches post. You'll need about 200 grams (1 cup) of pulled pork with sauce for 2 sandwiches.
For the garlic herb butter
- 56 grams (4 tablespoons) unsalted butter melted
- 2 cloves garlic grated on a microplane
- 5 grams (2 tablespoons) fresh parsley roughly chopped
- 2 grams (½ teaspoon or a pinch) fine sea salt
For the mashed potatoes
- 2 medium russet potatoes about 400 grams or 14 ounces, boiled and peeled
- 56 grams (4 tablespoons) unsalted butter softened
- 15 grams (1 tablespoon) whole milk room temperature
- 3 grams (¾ teaspoon) fine sea salt
For the sandwiches
- 4 slices sourdough bread about ½ inch thick
- 4 slices muenster cheese
- 4 slices mozzarella cheese
- 30 grams (2 tablespoons) olive oil
- 14 grams (1 tablespoon) unsalted butter
Instructions
Make the pulled pork
- Prepare the pulled pork according to my Pulled Pork Sandwiches on Sourdough Hawaiian Rolls recipe.You'll need about 200 grams (1 cup) for the 2 sandwiches in this recipe. Warm it gently before assembling. The rest can be used for other recipes or freezes beautifully for up to 3 months.
Make the mashed potatoes
- Peel the potatoes.Cut them into 1-2 inch chunks. Place them in a saucepan.Cover them with cold water by about an inch.Add a generous pinch of salt.
- Bring to a boil over high heat.Then reduce to a simmer and cook for 12 to 15 minutes, until the potatoes are fork-tender.
- Drain well and return to the pot. Mash with a potato masher or fork until smooth.
- Add the softened butter and the room temperature milk. Mix until creamy.
- Season with salt and stir to combine. Set aside to cool slightly.
Make the garlic herb butter
- In a small bowl, combine the melted butter, grated garlic, chopped parsley, and salt. Stir to combine.
Assemble the sandwiches
- Spread the garlic herb butter on one side of all 4 slices of sourdough bread. The buttered side is the inside of the sandwiches.
- Grab a slice and, on the buttered side, layer 2 slices of muenster cheese, then a generous scoop of pulled pork, then 2 slices of mozzarella cheese.Repeat with another slice.
- Top both stacks with the remaining 2 slices of bread, buttered side facing the filling. You should have two assembled sandwiches with the unbuttered sides facing out.
Cook the sandwiches
- Spread a thin, even layer of mashed potatoes on the top outer side of each sandwich. Cover the entire surface edge to edge.Press the mashed potatoes inside all the nooks and crannies of the bread.
- Heat 1 tablespoon of the olive oil and 1 tablespoon of the butter in a clean cast iron skillet over medium heat, just until the butter is melted.- Medium heat is important here, instead of the typical low heat used for other grilled cheese sandwiches, because the mashed potatoes need it to become crispy.A 12" skillet can cook both sandwiches at once, but if your skillet is smaller, then cook one sandwich at a time.
- As soon as the butter has melted, place both sandwiches in the skillet, mashed potato side down. Cook for 4 to 5 minutes, or until the potato crust is deeply golden and crispy.The trick to a crispy potato crust is patience. Don't move the sandwich around in the pan, just let it sit and develop that golden color before flipping.
- While the first side cooks, spread mashed potatoes on the other outer side of each sandwich, just like you had done before.
- Add the remaining 1 tablespoon of olive oil and 1 tablespoon of the butter to the pan.As soon as the butter has melted, carefully flip the sandwiches with a spatula. Cook for another 4 to 5 minutes, or until the second side is golden and crispy and the cheese inside is fully melted.
- Transfer to a cutting board and let rest for 1 minute before slicing in half and serving. If not eating them immediately, I recommend placing the sandwiches on a wire rack so they don't become soggy on the side resting on the plate.
Notes
- This recipe is designed to use up leftover pulled pork from my Pulled Pork on Sourdough Hawaiian Rolls recipe. That recipe makes enough for the rolls and for these 2 sandwiches.
- If you have leftover mashed potatoes, they make great savory pancakes the next morning. Just form into patties and pan-fry until golden. Or you can eat them with more of the pulled pork as another meal.
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