This burger combines ground chorizo and 80/20 beef into a single patty, topped with homemade garlic aioli, aged white cheddar, and arugula on a toasted brioche bun. The chorizo does the heavy lifting on flavor — smoky, garlicky, and spiced with paprika — so you don’t need a long list of toppings to make it interesting. It’s a genuinely satisfying cookout burger that holds up whether you’re making four patties or fourteen.
Before you start
The two things that actually matter here are meat temperature and mix ratio. Start with cold chorizo and cold beef — warm fat smears instead of binding, and you’ll end up with patties that fall apart on the grill. Keep everything cold right up until you form the patties, then refrigerate them again for at least 20 minutes before cooking. On ratio: chorizo is already heavily seasoned and has a looser texture than ground beef, so going beyond a 50/50 split makes the patties harder to handle and can push the salt level too high. Stick close to equal parts. Because this is a pork-and-beef blend, internal temperature is non-negotiable — pull these at 160°F (71°C) with an instant-read thermometer. There’s no safe way to serve them pink.
Troubleshooting
- Patties crumble when you flip them: The chorizo fat is probably too warm, or you flipped too early. Let the patty cook undisturbed until it releases cleanly from the grate or pan — forced flipping tears the crust that holds it together.
- Burger tastes aggressively salty: Spanish chorizo brands vary a lot in salt content. If yours is on the saltier side, skip any added salt in the patty mix entirely and taste the raw mix before forming.
- Aioli is sharp and harsh: Raw garlic needs time. If you’re serving within the hour, grate the garlic finer or mash it to a paste with a pinch of salt — more surface area means faster mellowing.
- Brioche bun goes soggy fast: Toast the cut sides in a dry pan until they’re genuinely golden, not just warm. A properly toasted brioche holds up for 10–15 minutes; an under-toasted one collapses in two. This matters a lot when you’re plating burgers in batches for a crowd.
- Cheddar won’t melt evenly: Add the slice when the patty is about 1 minute from done, then cover the pan or close the grill lid. Trapped heat melts the cheese without overcooking the meat.
Smart swaps
- Spanish vs. Mexican chorizo: These are not interchangeable. Spanish chorizo is cured and firm; Mexican chorizo is raw and loose. This recipe uses raw ground chorizo (or Spanish-style fresh chorizo removed from its casing). If you use Mexican chorizo, reduce or skip the smoked paprika — it’s already chili-forward and will tip the spice level quickly.
- Aged white cheddar: A good substitute is Manchego, which leans into the Spanish angle, but it doesn’t melt as smoothly. Gruyère melts better and adds a nutty note that works well here. Skip processed American-style slices — they melt fine but disappear into the chorizo flavor.
- Arugula: Baby spinach is milder and works if you don’t want the peppery bite. Watercress is a closer match to arugula’s sharpness.
- Brioche bun: A sturdy potato roll holds up better if you’re transporting burgers to a cookout. Brioche is ideal fresh off the grill but goes soft quickly in a covered tray.
Keeping and reheating
Formed raw patties keep in the fridge for up to 24 hours, stacked with parchment between them. Cooked patties store well for 3 days in an airtight container in the fridge — reheat them in a covered skillet over medium-low with a splash of water to create steam, which keeps them from drying out; aim for 2–3 minutes per side until the center hits 165°F. For freezing, freeze raw patties on a flat tray first, then transfer to a zip bag; they’ll keep for up to 2 months. Thaw overnight in the fridge before cooking — don’t cook from frozen or the outside scorches before the center is safe. The aioli keeps refrigerated for up to 4 days in a sealed jar; the garlic flavor intensifies over time, which is actually a bonus.
Smoky Chorizo Burger with Garlic Aioli
Ingredients
For the Chorizo Patty Mixture:
- 8 oz raw Spanish-style chorizo sausage casings removed
- 8 oz ground beef (80/20 blend preferred) freshly ground for ideal texture
- 1 tsp smoked paprika for enhanced smoky depth
- ¼ tsp kosher salt
- ½ tsp freshly cracked black pepper
For the Garlic Aioli:
- ½ cup mayonnaise preferably full-fat
- 2 cloves garlic minced or grated
- 1 tbsp lemon juice freshly squeezed
- ¼ tsp salt or to taste
To Assemble the Burgers:
- 4 pieces brioche buns lightly toasted
- 4 slices sharp cheddar cheese aged white cheddar melts beautifully
- 1 cup baby arugula washed and dried
- 1 medium heirloom tomato sliced; optional, for brightness
Instructions
- Prepare the Chorizo Patty Mixture: In a large bowl, combine the raw chorizo (casings removed), ground beef, smoked paprika, kosher salt, and pepper. Mix until just combined using your hands — don’t overwork it to maintain tenderness.
- Form the Patties: Divide the mixture into 4 even portions and shape into round patties about 1/2 inch thick. Press a small dimple in the center of each patty to prevent bulging during cooking. Refrigerate for 15 minutes to firm up.
- Prepare Garlic Aioli: While patties chill, mix mayonnaise, garlic, lemon juice, and salt in a small bowl. Taste and adjust seasoning. Refrigerate to let flavors develop.
- Cook the Patties: Preheat a cast-iron skillet or grill over medium-high heat (around 400°F / 200°C). Cook patties for about 3–4 minutes per side, flipping once, until golden and cooked through (internal temp should reach 160°F / 71°C). Add cheddar slices during the last minute to melt.
- Toast the Buns: Lightly butter the brioche buns and toast them cut-side down on the skillet or grill until golden (about 1 minute).
- Assemble: Spread garlic aioli on both halves of the bun. Add the chorizo patty, top with arugula and tomato slices. Crown with the top bun and serve hot.
Notes
- You can substitute Mexican-style chorizo for Spanish, but reduce the paprika or omit to balance the spice.
- For a smoky twist, add a slice of grilled red bell pepper or caramelized onions.
- Want a Leaner Patty? Try half ground turkey with chorizo but use a binder like 1 beaten egg.
- Letting the garlic aioli sit for at least 15 minutes enhances flavor depth.
Nutrition
Common questions
Can I make the patties ahead for a cookout?
Yes — form them the night before and refrigerate on a parchment-lined tray, covered tightly. Cold patties also hold their shape better on a hot grill, which is a real advantage when you’re cooking in batches.
How do I know when the patties are done without cutting into them?
Use an instant-read thermometer and pull them at 160°F (71°C) — this is a pork-and-beef blend, so that temperature is required, not optional. The thermometer takes the guesswork out completely, especially useful when you’re cooking a dozen patties and can’t watch each one closely.
Can I cook these on a flat griddle instead of a grill grate?
A flat griddle or cast-iron skillet actually works better for this mix because the chorizo fat renders out and can fall through grill grates, causing flare-ups. The flat surface also gives you a better sear on the patty’s full surface.
What’s the best way to scale this up for a large group?
Mix the meat in batches of no more than 2 pounds at a time — a bigger mass warms up too fast and gets overworked. Form all the patties first, refrigerate them in a single layer, and cook in waves rather than crowding the grill.
Can I use turkey or chicken instead of beef to lighten it up?
You can replace the ground beef with ground turkey, but add one egg to the mix to help it bind — turkey is leaner and the patties will crack without it. Cook to 165°F (74°C) internal, and expect a slightly firmer texture.
My store only has whole chorizo links. Can I use those?
Yes — just slit the casings and squeeze the meat out before mixing with the ground beef. Make sure you’re buying fresh (raw) chorizo links, not the dry-cured slicing kind, which won’t mix into a patty.
More burger recipes to try
- Five Guys Cajun Burger
- Spicy Jalapeño King Burger
- Angus Bacon Guacamole Burger
- Ultimate Guacamole Bacon Burger