House-Smoked Brisket Sandwich with Pickled Onions and BBQ Aioli

By AislePrompt Test Kitchen · Reviewed by AislePrompt Editorial · Published 2026-05-13 · Updated 2026-05-13

Slow-smoked brisket piled high on a soft bun, layered with tangy pickled red onions and a smoky barbecue aioli for a diner-style indulgence. This american-inspired sandwiches & wraps ready in about 405 minutes blends trimmed beef brisket, hickory or oak smoke wood chips, kosher salt into a versatile sauce that lifts everything from grain bowls and roasted vegetables to grilled proteins — a small-batch staple worth keeping in the fridge. Each serving lands at about 620 calories and feeds 4, so a small batch covers several meals across the week without taking over the fridge. Tap "Plan a meal with the AI" below to drop this recipe into your week and send the ingredients straight to Instacart. Nutrition values are approximate, calculated from USDA FoodData Central (fdc.nal.usda.gov) — verify against ingredient labels for any health-driven dietary plan.

Ingredients

• 2 lbs, trimmed beef brisket
• 2 cups, hickory or oak smoke wood chips
• 1 tbsp kosher salt
• 1 tbsp, freshly ground black pepper
• 2 tsp smoked paprika
• 1 tsp garlic powder
• 1 medium, thinly sliced red onion
• 1/2 cup apple cider vinegar
• 1 tbsp granulated sugar
• 1/3 cup mayonnaise
• 2 tbsp BBQ sauce
• 1/2 tsp smoked paprika
• 4 soft sandwich buns
• 2 tbsp, melted butter

Instructions

1. Step 1: Combine 1 tbsp kosher salt, 1 tbsp freshly ground black pepper, 2 tsp smoked paprika, and 1 tsp garlic powder in a bowl. Rub this spice mix evenly over 2 lbs trimmed beef brisket. Let it rest at room temperature for 30 minutes.
2. Step 2: Prepare your smoker with 2 cups hickory or oak wood chips and preheat to 225°F. Smoke the brisket fat side up for 5-6 hours until internal temperature reaches 195°F and the meat is tender.
3. Step 3: While brisket smokes, make pickled onions by combining 1/2 cup apple cider vinegar, 1 tbsp granulated sugar, and a pinch of salt in a small saucepan. Bring to a simmer until sugar dissolves, then pour over 1 thinly sliced medium red onion in a jar. Let cool and refrigerate for at least 1 hour.
4. Step 4: Mix 1/3 cup mayonnaise, 2 tbsp BBQ sauce, and 1/2 tsp smoked paprika in a bowl to create BBQ aioli.
5. Step 5: Once brisket is rested for 15 minutes, slice thinly. Lightly brush 4 sandwich buns with 2 tbsp melted butter and toast them on a hot skillet until golden, about 1-2 minutes per side.
6. Step 6: Assemble sandwiches by spreading BBQ aioli on both bun halves, layering sliced brisket, and topping with pickled onions. Serve immediately.