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Cheesy tri tip sandwich with horseradish aioli.

Grilled Tri Tip Sandwich & Horseradish Aioli

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Grab a hold of this juicy grilled Tri Tip Sandwich, topped with creamy Havarti cheese, zesty horseradish aioli, and tangy pickled red onions. This bold combination of flavors is held together with a toasty bun, the perfect vehicle to go full speed toward your mouth. All you’ll need is an ice-cold beer to wash it down.

  • Total Time: About 90 minutes
  • Yield: About 6-8 1x




  1. Season the tri-tip steak. Season all sides of the steak generously and allow it to sit at room temperature for about 20 minutes prior to grilling. 
  2. Prepare the grill for 2-zone cooking at around 250°F. Light the coals and set them on one side of the grill, leaving the other side without direct heat. Add chunks of hardwood if using to the coals.
  3. Smoke the tri-tip steak. Place the steak on the cool side of the grill away from the coals. Make sure the thickest part is the closest to the fire so that the thinner side doesn’t overcook. Allow the steak to cook with the lid closed for about 40-60 minutes until it reaches around 115-118°F (for medium-rare).
  4. Lift the lid and sear the steak. Allow the coals to start burning hotter by lifting the lid off the grill. Move the steak to the hot side of the grill and allow it to sear for 1 minute. Flip the steak and continue to repeat this process until the steak reaches your target temperature, about 128-130°F for medium rare. NOTE: If the steak is searing too quickly, move it to the cooler side for a minute to slow down the cooking. It’s best to take your time rather than burn the outside. Move it back over the heat and continue searing when ready.
  5. Allow the steak to rest before slicing. Give it about 10-15 minutes to rest at room temperature. This will allow the juices to be redistributed. Slice against the grain.
  6. Toast the bread on the grill. Butter up the slices of bread and grill them for 2-3 minutes, until it’s lightly toasted.
  7. Assemble the sandwich. Slather the horseradish aioli on each side of the bread and pile on the tri-tip to one half of the sandwich. Melt the cheese by placing the sandwich half with cheese on the cooler side of the grill, or use an oven broiler with a baking sheet. Top with onions and assemble the sandwich. Enjoy!


  • Author: Brad Prose
  • Prep Time: 20 minutes
  • Cook Time: 60 minutes
  • Category: Burgers & Sandwiches
  • Method: Grilling
  • Cuisine: Beef Sandwich
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