This Cheese Stuffed Choripan is twist on classic South American Choripan. This meat lovers’ sandwich is made of provolone-stuffed hoagie rolls topped with chorizo sausage, tomato chimichurri, and spicy habanero mayo.

two halves of a cheese stuffed choripan sandwich held over a fire

If you love this choripan recipe, you’ll love my Loaded Choripan too!

Let’s Get Rolling

First up, let’s prep the cheese stuffed rolls. Start with 5-6 small sandwich rolls. I recommend hoagie rolls or baguette rolls, because their size and shape is perfect for this Cheese Stuffed Choripan.

Separate the top roll from the bottom. Pull the excess bread from the center of the bottom roll to create a divot, then stuff each divot with the provolone cheese.

Next, layer the cheese stuffed roll with a handful of ground chorizo sausage. Be sure to spread the sausage all over to completely cover the cheese.

five hoagie rolls covered in chorizo sausage lined on a cutting board

Repeat with the remaining rolls, then place them into the fridge for 15-20 minutes. Don’t skip the chilling time. It gives the meat some time to firm up before cooking. Cook too soon and the sausage will just fall apart.

Get Saucy for Cheese Stuffed Choripan

While you wait for your buns to chill, grab a large bowl and make your tomato chimichurri. It’s super simple and perfect for these sandwiches!

So, add in chopped parsley, red wine vinegar, diced tomatoes, minced garlic, red chili flakes, and black pepper. Mix it all up, then add in little bits of olive oil at a time to give it a “saucier” consistency. Give the chimichurri a quick taste, then add salt as needed.

Looking for more chimichurri recipes? Try my Spiced Lamb Kebabs with Mint Chimichurri or Brazilian Steaks with Habanero Chimichurri.

Next up, the Habanero Mayonnaise for the Cheese Stuffed Choripan, because can you ever go wrong with more sauces? I don’t think so.

Grab a separate bowl, then mix together mayonnaise, garlic paste, and habanero hot sauce. Taste and adjust as needed, then it’s ready to go!

Grill It!

Now, it’s time to cook our Cheese Stuffed Choripan, because I know we’re all getting hungry.

Preheat a medium heat fire to around 325ºF for direct grilling. Remove the cheese stuffed rolls from the fridge, then place them onto the grill. Be sure that the chorizo side is facing down so it gets nice and cooked.

cheese stuffed choripan bottom buns being cooked face down on a grill grate

grilled chorizo covered rolls on a grill grate from above

Let the rolls cook for 15-17 minutes, then use a meat thermometer to check that the internal temperature is at least 165ºF. Adjust as needed to prevent flare-ups from burning the Cheese Stuffed Choripan. It’s just not quite as good burnt to a crisp. 😉

Pull the cooked sausage bread off of the grill, then set it aside. To the grill, add on the top buns and allow them to get nice and toasty.

Assemble and Serve Your Cheese Stuffed Choripan

Now, it’s time to assemble the sandwiches!

Simply lay the cheese-stuffed bottom buns out onto a plate, top each with a spoonful of tomato chimichurri and a drizzle of habanero mayonnaise, then layer on the top bun to finish out the Cheese Stuffed Choripan!

Now dig in!

five chorizo covered buns topped with tomato chimichurri

For more delicious recipes, check out my second cookbook Flavor X Fire or my first cookbook Food X Fire!

Needing more spice in your life? My spice line can help with that. Check them out here.

two halves of a cheese stuffed choripan sandwich held over a fire

Cheese Stuffed Choripan

This Cheese Stuffed Choripan is made of provolone-stuffed hoagie rolls topped with chorizo sausage, tomato chimichurri, and spicy habanero.
Author:Derek Wolf
5 from 1 vote
Prep Time: 30 minutes
Cook Time: 30 minutes
Total Time: 1 hour
Course: Main Course
Cuisine: South American
Servings: 4 people



  • 2-3 lbs Ground Chorizo Sausage
  • 10-12 Sliced Provolone Cheese
  • 5-6 Small Sandwich Rolls hoagie or baguette

Tomato Chimichurri:

  • ½ cup Parsley chopped
  • ¼ cup Red Wine Vinegar
  • ¼ cup Diced Tomatoes
  • 4-6 Garlic Cloves minced
  • 1 tbsp Red Chili Flakes
  • 1 tsp Black Pepper
  • Olive Oil to desired consistency
  • Salt to taste

Habanero Mayonnaise:

  • ½ cup Mayonnaise
  • 1 tbsp Garlic Paste
  • 1 tbsp Habanero Hot Sauce


  • Begin by slicing your small sandwich rolls in half and separating the top from the bottom (set the tops to the side to be used later). Next, carefully pull out the excess bread from the bottom half so that you create a divot in the bun. Stuff the divot with provolone cheese, then take a handful of your ground chorizo sausage and cover the cheese with it. Make sure to spread out the ground sausage all over the bread so it completely covers the cheese. Once done, set that to the side and begin working on the next roll until all the rolls are completed. Once all the rolls are done, place them in the fridge for 15-20 minutes to firm up.
  • In another bowl, mix together all the ingredients for the chimichurri sauce. Set to the side. Again in another bowl, mix together the ingredients for your Habanero Mayonnaise. Set to the side.
  • Preheat a medium heat fire (around 325F) for direct grilling.
  • Take out the bread and place it over the coals with the chorizo face down. Cook over the heat for about 15-17 minutes until the sausage is 165F internal or completely cooked through. If you have flare ups, make sure to move the bread around in order to prevent them. Once done, pull the sausage bread off and keep warm until ready to use. At this time, add the top buns to the grill and cook till they are nice and golden brown.
  • Serve the Cheese Stuffed Choripan with some tomato chimichurri, habanero mayonnaise and the top bun. Enjoy!


Calories: 957kcal | Carbohydrates: 43g | Protein: 41g | Fat: 67g | Saturated Fat: 30g | Polyunsaturated Fat: 14g | Monounsaturated Fat: 9g | Trans Fat: 0.1g | Cholesterol: 205mg | Sodium: 4395mg | Potassium: 301mg | Fiber: 3g | Sugar: 2g | Vitamin A: 2830IU | Vitamin C: 57mg | Calcium: 512mg | Iron: 6mg

Derek Wolf

Derek is the driving force behind Over the Fire Cooking. He started cooking with live fire in 2016 and decided to start a social media page so his friends and family could follow the journey. Fast forward to today and Over the Fire Cooking has spread across multiple platforms with millions now following Derek's fire cooking journey. He's a southern fellow who enjoys everything from classic BBQ to Central and South American inspired dishes. Whatever he's cooking up, it's guaranteed to be so freakin' delicious!

5 from 1 vote (1 rating without comment)

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  1. Looks fantastic tried recipe and was great made a change with the bread bun top and toasted this while basting it with garlic butter fantastic taste gives it that extra element on your taste buds thanks for the recipe