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Learn how to make the ultimate smoked tri-tip sandwich with garlic mayo—a surefire way to become the hero of your next backyard BBQ! This easy recipe is packed with flavor and perfect for any occasion.

BBQ Smoked Tri Tip Sandwich with Lemon Garlic Mayo

Table of Contents

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See the video

Scroll to the bottom of the page for a printable recipe…

Closeup of caramelized onions on Smoked Tri Tip Sandwich

What to put on tri tip sandwiches

Meat – thinly sliced tri-tip
Topping – Caramelized onions
Sauce – aioli, mayo, or chimichurri
Greens – arugula or mixed greens for a peppery bite and freshness
Bread – Toasted baguette, ciabatta, French roll, or sourdough
Optional – provolone cheese, grilled jalapenos, roasted red pepper

Baguette Sandwich with Tri Tip Mayo Arugula and Onions

Also see how to make smoked tri tip pizza…

Ingredients

For the Tri Tip

2.5 lb tri-tip steak
1 tbsp mustard (or olive oil)
2 tbsp BBQ rub

For the Caramelized Onions

1 large yellow onion, sliced into ½-inch strips
½ tbsp olive oil
1 tbsp butter

For the Grilled Lemon Garlic Mayo

1 medium lemon, halved
½ tsp garlic salt
¼ tsp freshly cracked pepper
½ tbsp fresh chopped basil (or cilantro)
½ cup mayonnaise

For the Sandwich

1 large French baguette
1 cup arugula

BBQ Smoked Tri Tip Sandwich with toppings

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How to make BBQ smoked tri tip sandwich

The gist of it: Rub a 2.5 lb tri-tip with mustard and BBQ seasoning, smoke it to perfection, and sear for a delicious crust. Add caramelized onions, arugula, and that flavorful mayo to a toasted baguette.

1. Prepare the Tri-Tip

Let the tri-tip steak rest at room temperature for 20 minutes.
Preheat your smoker or oven to 250°F.
Rub the mustard or olive oil over the tri-tip, then apply the BBQ rub evenly.

2. Smoke the Tri-Tip

Place the tri-tip on the smoker or in the oven.
Smoke or bake tri tip at 250°F for 45-60 minutes, until the internal temperature reaches 115-120°F.
Remove from heat and let the tri-tip rest for 10 minutes.

3. Caramelize the Onions

While the tri-tip cooks, heat a skillet over medium heat.
Add the sliced onions, olive oil, and butter to the skillet.
Sauté the onions, stirring regularly, for 5-10 minutes until they are caramelized and browned to your liking.

4. Grill the Baguette and Lemon

Slice the baguette into 2-3 sections, then slice each section in half lengthwise.
Preheat the grill to medium-high heat.
Place the lemon halves cut-side down on the grill for about 3 minutes over direct heat, until lightly charred.
Place the cut side of the baguette on the grill grates and grill for 1-3 minutes over indirect heat, until lightly toasted. Set aside.

grilling baguette and lemon before and after

5. Make the Grilled Lemon Garlic Mayo

Remove the lemon from the grill and squeeze the juice into a bowl.
Add garlic salt, freshly cracked pepper, chopped basil, and mayonnaise. Whisk until well combined.

6. Sear the Tri-Tip

Increase the heat on the smoker, grill, or skillet (with some butter in it) to 450-500°F.
Sear the tri-tip on all sides, flipping every 1-2 minutes until a crust forms and the internal temperature reaches your desired doneness (130°F for medium-rare).
Let the tri-tip rest for another 10 minutes, then slice thinly.

New to preparing tri tip? THIS IS IMPORTANT! See how to cut tri tip steak…

Thin Sliced Smoked Tri Tip Sandwich Meat

7. Assemble the Sandwich

Spread the grilled lemon garlic mayo on each side of the toasted baguette.
Layer the thinly sliced tri-tip on the bottom half of the baguette.
Add a layer of caramelized onions and top with a handful of arugula.
Close the sandwich with the top half of the baguette and serve.
Enjoy your delicious smoked tri-tip sandwich!

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How to reheat tri tip sandwich

Wrap the sandwich in aluminum foil. Heat it in the oven at 350°F for 10-15 minutes, or until the sandwich is warmed through. To crisp the bread, remove foil and bake a couple more minutes.