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Grilled Breakfast Casserole

Grilled Breakfast Casserole with smoky, char-kissed edges—eggs set low and slow on the grill while sausage, peppers, and hash browns crisp underneath. Layered with melty sharp cheddar and Monterey Jack for a warm, hearty crowd-pleaser.
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Prep Time 20 minutes
Cook Time 40 minutes
rest 5 minutes
Total Time 1 hour 5 minutes
Servings: 10 servings
Course: Breakfast
Cuisine: American
Calories: 610
Ingredients Equipment Method Notes

Ingredients
  

Base
  • 6 eggs
  • 0.5 cup whole milk
  • 0.5 tsp garlic powder
  • 0.5 tsp onion powder
  • 0.5 tsp smoked paprika
  • 0.5 tsp salt
  • 0.25 tsp black pepper
Filling
  • 1 lb breakfast sausage casings removed
  • 3 cup frozen hash browns thawed
  • 1 yellow onion medium, diced
  • 1 red bell pepper diced
  • 1 green bell pepper diced
  • 2 tbsp olive oil
Topping
  • 2 cup shredded sharp cheddar cheese
  • 0.25 cup shredded Monterey Jack cheese
  • 2 tbsp fresh chives chopped for serving
  • 1 sour cream or hot sauce for serving (optional)

Equipment

  • 1 cast iron skillet

Method
 

Prep and preheat
  1. Preheat your grill to medium heat, around 375°F / 190°C, and set up for indirect grilling with one side heated and the other side off.
  2. If using frozen hash browns, thaw them so they’re ready to spread into the skillet.
Cook sausage and vegetables
  1. Heat 1 tbsp olive oil in a cast iron skillet over the direct heat side, then add the breakfast sausage and cook for 6–8 minutes, breaking it apart, until browned and cooked through.
  2. Remove the cooked sausage from the skillet and set it aside.
  3. Add the remaining 1 tbsp olive oil to the same skillet, then cook the diced onion and bell peppers for 3–4 minutes until softened and lightly charred at the edges.
  4. Add the thawed hash browns and spread into an even layer, then cook undisturbed for 4–5 minutes until a golden crust forms on the bottom.
  5. Return the cooked sausage to the skillet and stir to distribute everything evenly.
Add egg base and cheese
  1. In a bowl, whisk the eggs, whole milk, garlic powder, onion powder, smoked paprika, salt, and black pepper until well combined, then pour the egg mixture evenly over the skillet filling.
  2. Sprinkle the shredded sharp cheddar and Monterey Jack over the top in an even, generous layer.
Grill low and slow, then rest
  1. Move the skillet to the indirect heat side of the grill, close the lid, and cook for 20–25 minutes until the eggs are fully set in the center and the cheese is melted, bubbly, and golden at the edges.
  2. Remove the skillet from the grill and let it rest for 5 minutes, then top with fresh chives and serve with sour cream or hot sauce if desired.

Notes

Pro tip: thaw hash browns for better browning and even egg set, and keep the lid closed during the 20–25 minute cook so the top melts properly. Store leftovers in the fridge up to 3 days in a covered container; reheat in a skillet over medium-low until warmed through. Freezing: not recommended for best texture. Dietary swap: use turkey sausage instead of breakfast sausage to reduce saturated fat while keeping the savory flavor.