Loaded Open-Faced BBQ Pulled Pork Sandwiches
These loaded open-faced BBQ pulled pork sandwiches are one of my favourite ways to turn leftover pork shoulder into an easy new dinner. A slow-cooked pork shoulder makes a generous amount of tender shredded pork, so you can usually stretch it into several meals instead of serving the same dinner again and again.
For this recipe, the leftover pulled pork is gently reheated with a little reserved pork cooking stock to keep it moist and flavourful. It is piled high on toasted hamburger buns, then topped with smoky barbecue sauce, warm homemade cheddar sauce, crispy fried onions, fresh jalapeño slices and herbs. The combination is messy, cheesy and really satisfying.
This is the kind of leftover pulled pork recipe that does not feel like leftovers at all. Serve these easy BBQ pork sandwiches for a quick weeknight dinner, casual lunch or game-day meal. One pork shoulder can go a long way, and this is definitely one of the tastiest ways to use it.
Short Description of the Recipe
These loaded open-faced BBQ pulled pork sandwiches are an easy way to turn leftover pork shoulder into a completely different meal. The shredded pork is gently reheated with a little reserved cooking stock, then piled onto toasted hamburger buns with smoky barbecue sauce, warm homemade cheddar sauce, crispy fried onions, jalapeño slices and fresh herbs.
They are cheesy, saucy and generously loaded. Definitely a knife-and-fork sandwich.
Why It’s Good
This leftover pulled pork sandwich recipe is especially good because it uses ingredients you may already have after cooking a large pork shoulder. Pork shoulder usually makes a lot of meat, and it can easily be stretched into several lunches and dinners without every meal tasting the same.
Adding a little reserved pork stock while reheating keeps the shredded pork tender and juicy. I found that adding the stock gradually works best—you want moist pork, not liquid pooling on the bun. The toasted hamburger buns hold up well under the meat, barbecue sauce and creamy cheddar sauce, while the crispy onions add a really nice crunch.
The jalapeño slices cut through some of the richness too. You can add just a few or pile them on.
When to Serve It
These open-faced pulled pork sandwiches are perfect for an easy weeknight dinner when you need to use up leftover pork shoulder. They also make a hearty weekend lunch, casual family meal or fun game-day dinner.
Serve them with coleslaw, potato salad, baked beans, fries or a simple green salad. They are also a good choice when feeding a crowd because the pork and sauces can be warmed ahead of time, then everyone can add their own toppings. Keep extra napkins nearby. These sandwiches are deliciously messy.
The Main Ingredient for Loaded Open-Faced BBQ Pulled Pork Sandwiches
Shredded Pork Shoulder—the Main Ingredient
Tender shredded pork shoulder is the main ingredient in these loaded open-faced BBQ pulled pork sandwiches. After slow cooking, the pork becomes soft enough to pull apart easily with two forks or a meat shredder. I like to remove any larger pieces of fat as I go, while leaving a little of the cooking juice mixed into the meat for extra flavour.
This generous pile of leftover pulled pork is moist, savoury and perfect for reheating with a splash of reserved pork stock. Pork shoulder makes a lot, which is one of the best things about it. You can enjoy the original pork dinner first, then use the leftovers for BBQ pulled pork sandwiches, tacos, pasta, rice bowls or soup.
Tips and Tricks
- Reheat the leftover pulled pork gently. Add a few spoonfuls of reserved pork cooking stock to the shredded pork and warm it over medium-low heat. Add the stock gradually. You want the pork moist and juicy, not sitting in a puddle of liquid.
- Remove larger pieces of fat while shredding. Pork shoulder usually has a little extra fat mixed through it. I pick out the larger pieces but leave the soft, flavourful bits that keep the pulled pork tender.
- Toast the hamburger buns well. These loaded open-faced BBQ pulled pork sandwiches have plenty of sauce, so the buns need a lightly crisp surface. A soft, untoasted bun can become soggy quite quickly.
- Warm both sauces before assembling. Cold barbecue sauce or cheddar sauce can cool the pork down fast. Gently warming the sauces also makes them easier to drizzle over the sandwiches.
- Thin the cheddar sauce when necessary. Homemade cheddar sauce often thickens in the refrigerator. Reheat it slowly with a small splash of milk until it becomes smooth and pourable again. Do not let it boil, or the sauce may separate.
- Add the crispy fried onions last. They give these pulled pork sandwiches a really good crunch, but they soften once they sit under the warm sauce. Sprinkle them on immediately before serving.
- Adjust the heat to suit your family. Fresh jalapeño slices add colour and help balance the rich pork and cheese sauce. Remove the seeds for less heat, serve them on the side or leave them off completely.
- Do not assemble the sandwiches too early. Keep the toasted buns, pork, sauces and toppings separate until everyone is ready to eat. The open-faced pulled pork sandwiches are best served hot and freshly loaded.
- Plan another meal with the leftovers. A large pork shoulder can stretch into several easy dinners. Any remaining shredded pork can be used for pulled pork tacos, quesadillas, rice bowls, pasta or soup.
Variations
- Make classic BBQ pulled pork sandwiches. Use both halves of the toasted hamburger buns and serve them as regular closed sandwiches instead of open-faced. Add extra barbecue sauce and a spoonful of coleslaw for a familiar pulled pork dinner.
- Try different barbecue sauces. A smoky, sweet or spicy BBQ sauce will each give these leftover pulled pork sandwiches a slightly different flavour. I like a thicker sauce because it stays on the pork instead of soaking straight into the bun.
- Use another cheese sauce. The homemade cheddar sauce is rich and creamy, but Monterey Jack, smoked Gouda or pepper Jack cheese sauce would also work well. Pepper Jack adds a little extra heat without needing many jalapeños.
- Turn them into pulled pork melts. Top the shredded pork with sliced cheddar or provolone, then place the sandwiches under the broiler for a minute or two. Watch them closely. The cheese can go from melted to overly browned pretty fast.
- Add a fresh, crunchy topping. Replace the crispy fried onions with creamy coleslaw, shredded cabbage or quick-pickled red onions. The acidity and crunch help balance the rich pulled pork and cheddar sauce.
- Make the sandwiches milder. Leave off the fresh jalapeño and use a sweet barbecue sauce. You can add sliced pickles instead for a little tang without the heat.
- Give them extra spice. Add pickled jalapeños, hot sauce, chipotle barbecue sauce or a pinch of cayenne to the shredded pork. A small amount is usually enough, especially when the cheddar sauce is already rich.
- Use a different bread. These loaded open-faced pulled pork sandwiches also work well on brioche buns, crusty rolls, Texas toast or thick slices of sourdough. Choose something sturdy enough to hold the juicy pork and sauces.
- Make pulled pork sliders. Spoon the reheated pork onto small slider buns and add barbecue sauce, cheddar sauce and crispy onions. These are great for parties, game-day snacks or casual family gatherings.
- Turn the leftovers into a pulled pork bowl. Skip the bun and serve the shredded pork over rice, mashed potatoes or roasted potatoes. Add barbecue sauce, cheddar sauce and crispy onions on top for an easy leftover pork dinner.
Storage Tips
- Store the pulled pork separately. Place the leftover shredded pork in an airtight container with a few spoonfuls of the reserved cooking stock. That little bit of liquid helps keep the pork moist instead of drying out in the refrigerator.
- Refrigerate the cooked pork promptly. Store the pulled pork in the refrigerator for up to 3 days, keeping in mind how long the original pork shoulder has already been stored. The storage time starts from the day the pork was first cooked, not from the day the sandwiches were assembled.
- Keep the toppings in separate containers. Store the barbecue sauce, cheddar sauce, jalapeños and fresh herbs separately. The crispy fried onions should remain at room temperature in a tightly sealed container so they stay crunchy.
- Do not store assembled sandwiches. Loaded open-faced pulled pork sandwiches become soggy fairly quickly once the sauces are added. Refrigerate the individual components and toast fresh hamburger buns when you are ready to serve them again.
- Reheat the pork gently. Warm the shredded pork in a covered skillet over medium-low heat with a small splash of reserved pork stock. Stir occasionally and add only enough liquid to loosen the meat. Too much stock can make the buns soggy.
- Reheat the cheddar sauce slowly. Homemade cheddar sauce thickens as it cools. Warm it over low heat and stir in a small splash of milk until it becomes smooth and pourable again. Avoid boiling it, as high heat may cause the cheese sauce to separate.
- Freeze extra pulled pork for another meal. Portion the cooled shredded pork into freezer-safe containers or bags with a little cooking stock. Freeze it for up to 2 months, then thaw it overnight in the refrigerator before reheating.
- Assemble just before serving. Toast the buns, warm the pork and sauces, then add the crispy onions, jalapeños and herbs at the very end. This keeps every leftover pulled pork sandwich hot, crunchy and fresh tasting.
Loaded Open-Faced BBQ Pulled Pork Sandwiches
Equipment
- Large skillet with lid
- Baking sheet
- Small saucepan
- Measuring cups and spoons
- Wooden spoon or silicone spatula
- Two forks or meat shredding claws
- Pastry brush, for buttering the buns
- Sharp knife
- Cutting board
- Serving platter
- Microwave-safe bowls, optional for warming the sauces
Ingredients
- 3 cups pork shoulder shredded and cooked and cooled
- ⅓ to ½ cup reserved pork cooking stock strained with excess fat removed
- ½ teaspoon smoked paprika optional
- ¼ teaspoon garlic powder optional
- Black pepper added to taste
- 4 hamburger buns split into 8 halves
- 1 tablespoon butter or olive oil for toasting the buns
- ½ cup barbecue sauce warmed
- 1 cup cheddar sauce homemade creamy and warmed (see my recipe for cheddar sauce)
- ½ cup fried onions crispy for topping
- 1 jalapeño fresh and thinly sliced
- 2 tablespoons fresh parsley finely chopped
- Fresh dill chopped or left in small sprigs, optional
Use Ellen Cooks’ homemade Creamy Cheddar Sauce for the warm, rich cheese topping. (Ellen Cooks) rich cheese topping.
Instructions
Reheat the shredded pork
- Place the shredded pork shoulder in a large skillet over medium-low heat. Pour in ⅓ cup of the reserved pork cooking stock.
- Cover and cook for 5 to 7 minutes, stirring occasionally, until the pork is hot and juicy. Add a little more stock if the meat still seems dry, but do not add so much that the pork becomes watery.
- Season with smoked paprika, garlic powder and black pepper, if needed. The leftover pork may already have plenty of seasoning, so taste it first.
Toast the hamburger buns
- Preheat the oven to 425°F.
- Arrange the hamburger bun halves cut-side up on a baking sheet. Lightly brush them with butter or olive oil.
- Toast for 4 to 6 minutes, or until the edges are lightly golden. Toasting the buns is important because it helps them hold the juicy pork and sauces without becoming too soft.
Warm the sauces
- Warm the barbecue sauce in a small saucepan or microwave-safe bowl.
- Gently reheat the creamy cheddar sauce over low heat. Stir in a small splash of milk if it has thickened too much.
Assemble the sandwiches
- Place a generous mound of warm shredded pork onto each toasted hamburger bun half.
- Drizzle the pork with barbecue sauce, followed by plenty of warm creamy cheddar sauce. Finish with crispy fried onions, sliced jalapeños and chopped fresh herbs.
- Serve immediately while the pork and cheddar sauce are warm and the onions are still crispy.
Notes
- Use cooked pork shoulder for the best pulled pork texture. Pork shoulder stays tender and juicy after slow cooking and shreds easily with two forks. Remove any large pieces of fat as you pull the meat apart.
- Save some of the pork cooking stock. A few spoonfuls of reserved stock help bring leftover shredded pork back to life. Add it slowly while reheating so the pork stays moist without becoming watery.
- Taste the pork before adding more seasoning. Leftover pork shoulder may already be well seasoned from the original dinner. A little black pepper, garlic powder or smoked paprika can be added if needed.
- Toast the hamburger buns before adding the toppings. These loaded open-faced BBQ pulled pork sandwiches are quite saucy. Toasted buns hold up much better under the pork, barbecue sauce and cheddar sauce.
- Warm the barbecue sauce. Warm BBQ sauce spreads more evenly over the pulled pork and helps keep the sandwich hot.
- Reheat the homemade cheddar sauce over low heat. If the sauce has thickened in the refrigerator, stir in a small splash of milk until it is smooth and pourable. Do not boil it.
- Add the cheddar sauce just before serving. The warm cheese sauce makes these cheesy pulled pork sandwiches rich and comforting, but it will soften the bun if it sits too long.
- Sprinkle the crispy fried onions on last. They add a really good crunch, especially against the tender shredded pork. They can soften quickly once they touch the warm sauce.
- Adjust the jalapeños to taste. Fresh jalapeño slices add a little heat and help balance the rich BBQ pork and cheddar sauce. Remove the seeds or serve them on the side for a milder sandwich.
- Serve these as a knife-and-fork sandwich. The pulled pork sandwiches are generously loaded and can be messy to pick up. That is part of what makes them so good.
- Assemble only what you plan to eat. Store the pulled pork, sauces and toppings separately, then toast fresh buns when serving the leftovers.
- One pork shoulder can make several meals. Use extra shredded pork for pulled pork tacos, quesadillas, rice bowls, pasta or another easy leftover pork dinner.
Nutrition
Ellen Britt
Hi, I’m Ellen — a passionate home cook dedicated to creating easy, flavorful recipes inspired by real-life cooking and shared family traditions. Every recipe on this site is a true collaboration, developed and tested together in our kitchen to ensure it’s reliable, simple to follow, and absolutely delicious.