Hawaiian BBQ Chicken Sandwiches

Alright, these Hawaiian BBQ chicken sandwiches? They’re sweet, smoky, tangy, and piled high with juicy shredded chicken. One bite, and you’re basically on island time.

I made them on a busy weeknight using leftover chicken and some bottled BBQ sauce. Added crushed pineapple for that tropical twist, toasted some buns, and built the sandwiches—and wow. They were messy in the best way.

You get tender chicken, sweet pineapple, melty cheese (if you want), and a soft bun that soaks it all up. It’s easy, quick, and full of flavor that feels way more exciting than your usual dinner.

Let’s get these sandwiches going—you’ll be dreaming of the next one before you finish the first.

Why You’ll Love This Recipe

• Flavor-Packed Layers: The combination of honey BBQ chicken with caramelized pineapple brings a contrast of sweet and smoky that makes every bite memorable.
• Quick & Reliable: There’s no long marinating time needed. The dry rub and BBQ sauce work quickly to flavor the chicken while it cooks.
• Grill or Stovetop Friendly: You can make these sandwiches outdoors on a grill or indoors with a grill pan—no fancy tools required.
• Restaurant-Worthy Presentation: Grilled pineapple rings and bright red onion slices elevate the look and taste, perfect for casual gatherings.
• Customizable Base: Add cheese, swap the bun, or use shredded chicken instead of fillets—this sandwich works with whatever you have.

What You Need to Know Before You Start

Prep Time: 15 minutes
Cook Time: 25 minutes
Total Time: ~40 minutes

This recipe moves quickly once you start, so prep your ingredients ahead of time. Slice the chicken breasts, prep the pineapple rings, and have the BBQ sauce and toppings ready before heating the grill.

Servings:
This recipe makes 4 hearty sandwiches. Each sandwich is filling on its own but pairs well with fries, sweet potato wedges, or a fresh slaw.

Difficulty Level:
Beginner-friendly. The only key is not to overcook the chicken or pineapple. Otherwise, everything comes together easily.

Required Kitchen Tools

• Grill or Stovetop Grill Pan: To achieve the caramelized char on the chicken and pineapple.
• Tongs or Spatula: For flipping chicken and pineapple.
• Small Mixing Bowl: To mix the pineapple juice and BBQ sauce.
• Sharp Knife & Cutting Board: For slicing chicken, onions, and prepping toppings.
• Basting Brush (Optional): Helps with applying sauce during cooking.
• Toaster or Skillet: For lightly toasting the burger buns if desired.

Ingredients for Hawaiian BBQ Chicken Sandwiches

Here’s a closer look at everything you’ll need (exact amounts will also appear in the recipe card):

• 2 large boneless, skinless chicken breasts, filleted horizontally to make 4 thinner pieces
  → Filleting makes the chicken cook evenly and fit perfectly in a sandwich without being too thick. You can pound them slightly with a meat mallet if needed.
• 1 packet KC Masterpiece Sweet Honey BBQ Sauce & Dry Rub
  → This gives the chicken a smoky-sweet, lightly spiced glaze that clings well when grilled. You’ll use the dry rub before grilling, and the sauce for brushing on during the last few minutes of cooking.
• 2/3 cup pineapple juice
  → This adds acidity and tropical sweetness to the BBQ sauce. It also tenderizes the chicken slightly when brushed on with the sauce.
• 4 pineapple slices, about ½-inch thick
  → Grilled until caramelized on the edges, these pineapple rings bring juicy sweetness and charred depth to the sandwich.
• 4 thick slices red onion
  → Grill these alongside the pineapple for texture and bite. They become sweeter and less sharp when grilled.
• 4 pieces of lettuce, such as butter lettuce, romaine, or green leaf
  → Adds a crisp, fresh contrast to the rich, saucy chicken.
• 4 burger buns, toasted if desired
  → Use brioche, potato, or Hawaiian sweet buns. Lightly toasting the inside of each bun prevents sogginess and adds a slight crunch.

Optional Additions for More Flavor:

• 1 tbsp olive oil, for brushing the grill grates or pineapple if you’re using a dry grill
• 1 tsp brown sugar, sprinkle over the pineapple slices before grilling to boost caramelization
• Mayo or chipotle aioli, to spread on the buns for extra richness

Variations for Hawaiian BBQ Chicken Sandwiches

These sandwiches are flexible and can be tailored to your taste or dietary needs. Here are a few creative twists:

• Use Shredded Chicken: If you have leftover rotisserie chicken, toss it in BBQ sauce and pineapple juice, then layer it on the bun with your toppings.
• Make It Spicy: Add sliced jalapeños, spicy BBQ sauce, or a dash of cayenne to the dry rub for heat lovers.
• Add Cheese: A slice of pepper jack, mozzarella, or smoked gouda melts beautifully over the grilled chicken and adds a creamy element.
• Gluten-Free Option: Use gluten-free buns or lettuce wraps instead of traditional burger buns.
• Low-Carb Swap: Serve the chicken, grilled pineapple, and toppings in a lettuce wrap or over a bed of slaw for a lighter meal.
• Vegetarian Version: Swap chicken for grilled portobello mushrooms or tofu, coated with the same rub and sauce.

How to Make Hawaiian BBQ Chicken Sandwiches

Step-by-Step Instructions

1. Prepare the Chicken

• Slice the Chicken: Start by slicing each chicken breast in half horizontally to create two thinner cutlets. This helps the chicken cook more evenly and gives a better sandwich-to-chicken ratio.
• Apply Dry Rub: Sprinkle the KC Masterpiece Dry Rub over both sides of the chicken. Use your hands to press it into the surface for even coating. Let it rest at room temperature for 10 minutes while you prepare the other ingredients.

2. Make the BBQ Sauce Blend

• In a small bowl, mix ½ cup of BBQ sauce with 2/3 cup pineapple juice. This thins the sauce slightly and infuses it with sweet tropical flavor.
• Optional: Pour the mixture into a small saucepan and simmer over medium heat for 5–7 minutes to reduce slightly for a stickier, thicker glaze.

3. Grill the Pineapple and Onion

• Brush lightly with oil and place the pineapple slices and red onion rounds on a preheated grill or grill pan over medium-high heat.
• Cook for 2–3 minutes per side, or until you see grill marks and light caramelization.
• Remove from heat and set aside on a plate.

4. Grill the Chicken

• Preheat your grill (or grill pan) over medium-high heat. Lightly oil the grates or pan.
• Place the chicken pieces on the grill. Cook for 4–5 minutes on the first side without moving.
• Flip and start brushing with the pineapple-BBQ sauce mixture. Cook for another 4–6 minutes, brushing with more sauce once or twice, until the chicken is fully cooked (internal temperature should read 165°F/74°C).
• Remove the chicken from the grill and let it rest for 5 minutes.

5. Toast the Buns (Optional but Recommended)

• Split the buns and toast them cut-side down on the grill or in a dry skillet until golden brown. This helps them hold up to the juicy fillings.

How to Serve Hawaiian BBQ Chicken Sandwiches

Assemble each sandwich in the following order for the best texture and bite:

1. Bottom Bun: Spread with mayo, chipotle aioli, or leave plain if preferred.
2. Lettuce Leaf: Helps shield the bun from juices and adds a crisp, cool base.
3. Grilled Chicken Breast: Brush with a final touch of warm BBQ-pineapple glaze.
4. Grilled Pineapple Slice: Adds juicy sweetness that cuts through the savory meat.
5. Grilled Red Onion Ring: Provides just the right amount of sharpness and texture.
6. Top Bun: Press gently and serve immediately.

Optional Garnishes:

• A toothpick to hold it together for presentation
• Extra sauce on the side
• Fresh cilantro or sliced green onions for a pop of green

Storing Hawaiian BBQ Chicken

• Cooked Chicken: Store leftover chicken in an airtight container in the refrigerator for up to 3–4 days. Reheat gently in a skillet or microwave.
• Grilled Pineapple/Onion: These can be stored in a sealed container in the fridge for up to 2 days.
• Fully Assembled Sandwiches: Best served fresh. If needed, store components separately and assemble just before serving to avoid sogginess.

Tips and Tricks for Success

• Slice Evenly: Thin, even chicken pieces cook more quickly and evenly, and fit better in the sandwich.
• Rest the Chicken: Always rest grilled meat for a few minutes to retain juiciness.
• Don’t Skip Toasting: A toasted bun prevents sogginess and adds texture.
• Use Tongs, Not Forks: Piercing the chicken while flipping can let juices escape. Use tongs or a spatula.
• Layer Thoughtfully: Placing lettuce beneath the chicken helps protect the bun from getting soggy.

Nutrition

Component	Per Serving (1 Sandwich)
Calories	480–520 kcal
Protein	32g
Carbohydrates	38g
Sugars	16g
Fat	22g
Saturated Fat	4g
Fiber	2g
Sodium	820mg
Cholesterol	85mg

Note: Nutrition values are approximate and depend on the brand of BBQ sauce and bun used.

Hawaiian BBQ Chicken Sandwiches FAQs

Can I use a different BBQ sauce?
Yes. If you don’t have KC Masterpiece, you can use any thick, sweet-style BBQ sauce. Just be sure it pairs well with pineapple and doesn’t lean too smoky or vinegar-heavy unless you like more tang.

What kind of buns work best?
Soft brioche or Hawaiian sweet rolls complement the sweet-savory flavors nicely. Potato buns are also a sturdy, neutral option that holds up well to the saucy fillings.

Can I cook the chicken on a stovetop if I don’t have a grill?
Absolutely. Use a stovetop grill pan or large cast-iron skillet. Cook over medium-high heat and follow the same timing instructions. You’ll still get great caramelization from the BBQ sauce.

Is it okay to use canned pineapple?
Yes. Canned pineapple rings in juice (not syrup) work well and are convenient. Just drain them thoroughly before grilling, and pat dry if needed to avoid excess moisture on the grill.

Can I make the chicken ahead of time?
You can grill the chicken up to 2 days in advance and store it in the fridge. Reheat it gently and brush with extra BBQ sauce before assembling your sandwiches.

Conclusion

These Hawaiian BBQ Chicken Sandwiches are the kind of meal that doesn’t just taste good—they bring a little joy with every bite. The tender chicken, sweet pineapple, and smoky BBQ sauce work together in perfect balance, making them ideal for weeknight meals, family cookouts, or whenever you want something fun without too much fuss.

Once you’ve made them once, you’ll find yourself coming back to this recipe again and again—not just for the flavors, but for how simple it is to pull off.