On our many frequent trips to and from Indiana University, we got in the habit of timing our stops conveniently at our favorite gas station which conveniently is part of a huge dairy farm and cheese market.
Minutes later, we’d be in the car, bellies full of generous samples of aged gouda, extra sharp cheddar, sweet swiss and more to take home and use in recipes like my homemade mac ‘n cheese.
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Also —they sell the most decadent cheesy grilled cheese sandwich that is coated with cheese on the outside. I vowed I would make my own version someday because I just couldn’t get out of my head.
Who knew the perfect grilled cheese used to live in Indiana? 😉 And has a brie, prosciutto and fig grilled cheese cousin?
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A great grilled cheese starts on the outside
There are three key ingredients, other than cheese, responsible for the crispy, slightly airy and flavorful exterior of this sandwich.
- Sourdough bread. A sturdy sourdough bread that isn’t too thick (but also isn’t too thin) makes for a top notch grilled cheese.
- Mayonnaise. A schmear of mayo —yup, mayo —on the outside of the bread is one of the secrets to a crispy flavorful crust.
- Fresh grated parmesan cheese. A heavy handed sprinkling of fresh grated parmesan cheese adds amazing texture and satisfying crunch.
Best cheese combo for grilled cheese
There’s lots of debate about the best melting cheese for grilled cheese. This blend, to me, gives the biggest bang for your grilled cheese buck:
- New York sharp cheddar. A classic New York cheddar brings tangy flavor and lends that classic bright orange you want to see.
- Sliced gruyere. A classic fondue cheese, thinly sliced gruyere is perfect for grilled cheese thanks to its nutty flavor and texture.
- Dubliner. An Irish cheddar style cheese with a sophisticated cheddar flavor, surprisingly great melting properties and a thicker quality.
Equipment needed
The difference between a good grilled cheese sandwich and a great one boils down to one simple tool. A cast iron skillet with a lid.
My favorite cast iron skillet comes from Lodge. And if you’re worried about how to care for cast iron, I’ve got an easy guide to help!
You also can use any lid you have that will fit.
Step-by-step method
The grilled cheese building process as much methodical as it is creative. And don’t let “methodical” scare you. It’s cooking 101 methodical. Not 400 level physics class methodical.
Assemble
- Heat a 10″ seasoned cast iron skillet over medium heat until the sides are hot to the touch but the pan shouldn’t be smoking. (For tips on seasoning cast iron, be sure to check out my Cast Iron 101 post.)
- Stack two slices of bread on each other so that they match in shape (like they are when you pull them out of the package (see? Methodical).
- Lay them stacked on a cutting board and slather the top slice facing you generously with mayo.
Cook
- Sprinkle on a good amount of fresh grated parmesan [1]
- Remove the cheese and mayo coated top slice and set it aside.
- Layer cheese on the bottom slice in the following order (again: methodical):
- NY cheddar
- gruyere
- Dubliner
- Flip the whole sandwich over into the preheated pan. Quickly slather over mayo and a sprinkling of parm on the other side and then…cover the pan. [2]
- Wait a painful five minutes before flipping over for 3-5 minutes more.
You —yes you!—have just made an amazing grilled cheese sandwich. [3]
Helpful Tips
Here are some extra tips to help you successfully make this recipe right from the start:
Make ahead, storage, reheating tips
Make ahead
You can make these sandwiches ahead of time and lay them on a rack set in a sheet pan. Refrigerate until you’re ready to make them (no more than 4 hours ahead or so).
Storing / Reheating
Wrap cooked sandwiches in foil and then place in ziploc bags. Store up to two days. To reheat, place sandwiches on a rack set inside a sheet pan and bake for 10 minutes or so at 350˚.
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Parmesan Crusted Grilled Cheese
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Equipment
- cast iron skillet with a lid
Ingredients
- 2 slices sourdough bread, preferably from a bakery
- 1 Tablespoon real mayonnaise, I use Hellman's; more as needed
- 1 Tablespoon freshly grated parmesan cheese, no green can please
- 2 slices sharp cheddar cheese, I use Adam's Reserve from Costco
- 3 slices gruyere cheese, thinly sliced
- 2 slices Dubliner cheddar
Instructions
- Heat a 10" seasoned cast iron skillet over medium (not medium-high) heat until the sides are warm to the touch. If the pan smokes, it’s too hot—turn it down. Too much heat will make the parmesan stick and burn. (For tips on seasoning cast iron, be sure to check out my Cast Iron 101 post.)
- Stack two slices of bread on each other so that they match in shape (like they are when you pull them out of the package.2 slices sourdough bread
- Lay the bread slices stacked on a cutting board. Spread a light-to-generous layer of mayo on the top slice (adjust depending on how large or soft your bread is).1 Tablespoon real mayonnaise
- Sprinkle on a good amount of fresh grated parmesan.1 Tablespoon freshly grated parmesan cheese
- Remove the cheese and mayo coated top slice and set it aside.
- Layer cheese on the bottom slice in the following order: NY cheddar, gruyere, Dubliner.2 slices sharp cheddar cheese, 3 slices gruyere cheese, 2 slices Dubliner cheddar
- Flip the whole sandwich into the preheated pan. Quickly slather the top slice with mayo and a sprinkling of parm. Cover the pan with a lid right away—this step is key. It traps heat so the parmesan melts into the bread instead of sticking to the pan. Don’t skip it.*Adjust your heat lower as needed.
- Wait a painful 5 minutes before flipping (make sure the bottom is golden brown and the cheese is starting to melt. Turn over, cooking for 3-5 minutes more while keeping the lid on the pan.
- Cut and make sure to photograph that big ole cheese pull!
I REALLY wanted to love this recipe, but by the time I was finished cooking just 3 sandwiches, I had gone through 4 pans (2 well seasoned cast irons and 2 Teflon pans). In every pan the parmesan cheese would immediately stick and burn onto the pan. There’s no way to get it to not stick to the pan. I may try this again, but next time I’ll definitely be broiling it from the top so the cheese can’t stick to anything other than the bread itself.
Also, I think it would be better with a minimal layer of mayo, not a “generous slab”, as the directions stated. Much of that generous slab soaked into the bread as it cooked and made the sandwich just overall soggy. If the reason you’re not using butter is because it has a low smoke point, then why not use a cooking oil, like grapeseed or olive oil instead? Those both have a high smoke point and would probably provide a much crisper, cleaner texture to the bread than mayo….
That said… thanks for posting this, but it’s a “no-go” for me.
Hi Linda! Thank you so much for taking the time to make the recipe and for sharing such detailed feedback — I know how frustrating it is when things don’t go as expected. Parmesan can be a little temperamental since it loves to stick, which is why I suggest keeping the heat at medium and covering the pan with a lid. The lid really helps the cheese melt into the bread instead of the pan.
And I hear you on the mayo! Bread types vary so much — sometimes a lighter touch is better to keep things crisp. I love that you’re thinking about different ways to make it your own.
With your feedback, I did refine the recipe card a bit to make sure the lid and heat are more clearly called out. I really appreciate you giving it a try, and I hope if you make it again with those tweaks, it’ll be a much smoother experience. Thanks you again, Linda!
Why use mayo instead of butter on a grilled cheese?
Mayo, believe it or not, doesn’t burn as easily as butter, adds a tangy flavor and creates a super crunchy exterior to the bread. Plus, it spreads way easier and you don’t have to melt butter😊
https://khak.com/a-midwest-city-is-hosting-a-grilled-cheesemac-cheese-festival/
I’m thinking if attending this with my friend Beth.. always room for more in my parties!!!
Ny mouth is watering just reading about this, can’t wait to try using mayo, thanks for the tip.
It is magic I must say! And this comes from someone who doesn’t put mayo on her sandwiches! Let me know what you think and thanks Barbara!
Lori, the best grilled cheese positively, undeniably ! The good sour dough bread with mayo and parmesan is what makes it.
Thank you
Right?! That combo is the secret sauce for the best grilled cheese sandwich! So happy you liked it Crystal!