Boilermaker chili is a big, thick, beefy pot of chili made with ground chuck and Italian sausage, four cans of chili beans, two kinds of bell pepper and a splash of beer, simmered low until it’s rich and smoky. Top it with crunchy corn chips and a pile of cheddar and it feeds a crowd on game day.
How to make boilermaker chili: brown the chuck and sausage, drain the grease, stir in the beans, tomatoes, vegetables, beer and spices, then cover and simmer on low for at least 2 hours.
Why You’ll Love It
- Feeds 10 from one large stock pot.
- Two meats. Ground chuck and Italian sausage in every spoonful.
- 30 minutes of work. After that, the pot just simmers while you do other things.
- Even better the next day, so you can make it ahead for a party.
Ingredient Notes
Meat. Two pounds of ground chuck and one pound of bulk Italian sausage, the kind sold loose rather than in casings, so it crumbles straight into the pot.
Chili beans. You need four 15-ounce cans. Drain three of them, but pour in the can of chili beans in spicy sauce with all its sauce.
Tomatoes. Two 28-ounce cans of diced tomatoes with their juice, plus a 6-ounce can of tomato paste.
Beer. Just 1/2 cup, stirred in with the vegetables.
The heat. It comes from several places at once: the spicy chili beans, two green chili peppers, hot pepper sauce and a teaspoon of cayenne. Bacon bits and four beef bouillon cubes go in with the vegetables.
Ingredients
- 2 pounds ground chuck
- 1 pound bulk Italian sausage
- 3 cans chili beans (15 ounces each), drained
- 1 can chili beans in spicy sauce (15 ounces), not drained
- 2 cans diced tomatoes (28 ounces each), with their juice
- 1 can tomato paste (6 ounces)
- 1 large yellow onion, chopped
- 3 stalks celery, chopped
- 1 green bell pepper, seeded and chopped
- 1 red bell pepper, seeded and chopped
- 2 green chili peppers, seeded and chopped
- 1 tablespoon bacon bits
- 4 beef bouillon cubes
- 1/2 cup beer
- 1/4 cup chili powder
- 1 tablespoon Worcestershire sauce
- 1 tablespoon minced garlic
- 1 tablespoon dried oregano
- 2 teaspoons ground cumin
- 2 teaspoons hot pepper sauce
- 1 teaspoon dried basil
- 1 teaspoon salt
- 1 teaspoon ground black pepper
- 1 teaspoon cayenne pepper
- 1 teaspoon paprika
- 1 teaspoon white sugar
- 1 bag corn chips (10 1/2 ounces), such as Fritos, for serving
- 1 package shredded cheddar cheese (8 ounces), for serving
How to Make Boilermaker Chili
1. Brown the meat. Heat a large stock pot over medium-high heat. Crumble the ground chuck and the sausage into the hot pan and cook until evenly browned and the beef reaches 160°F. Drain off the excess grease.
2. Build the pot. Pour in the chili beans, the spicy chili beans, the diced tomatoes and the tomato paste. Add the onion, celery, green and red bell peppers, chili peppers, bacon bits, bouillon and beer. Season with the chili powder, Worcestershire sauce, garlic, oregano, cumin, hot pepper sauce, basil, salt, pepper, cayenne, paprika and sugar. Stir to blend.
3. Simmer. Cover and simmer over low heat for at least 2 hours, stirring occasionally.
4. Taste and adjust. After 2 hours, taste and adjust the salt, pepper and chili powder if needed. Take it off the heat and serve, or refrigerate and serve the next day.
5. Serve. Ladle into bowls and top with corn chips and shredded cheddar.
How Long to Simmer, and How to Thicken It
Two hours, covered, over low heat is the minimum. Stir it occasionally while it cooks. If you have more time, give it more: the longer the chili simmers, the better it tastes, and another 1 to 3 hours builds an even deeper flavor.
When the simmer is done, look at the pot. If the chili is soupier than you like, take the lid off and let it bubble gently, uncovered, for 15 to 20 minutes.
For game day, it’s a make-ahead dish. Cook it the day before, refrigerate it, and reheat it on the stove over medium-low heat, stirring until it’s hot all the way through. It tastes great after a night in the fridge.
| Plan | What to do | Time |
|---|---|---|
| Stovetop | Covered, low heat, stir occasionally | At least 2 hours |
| Deeper flavor | Keep simmering after the first 2 hours | 1 to 3 hours more |
| Thicker chili | Simmer with the lid off at the end | 15 to 20 minutes |
| Day ahead | Refrigerate overnight, reheat on the stove over medium-low | Until hot |
Tips for Success
Why is my chili greasy?
You’ll see an orange layer of fat pooling on top. Two pounds of chuck and a pound of sausage give off a lot of grease, so drain it well after browning, before the beans and tomatoes go in.
Why does my chili taste flat?
It needs a final seasoning. Taste it after the 2 hours and add salt, pepper or chili powder a little at a time until it tastes right to you.
Variations
- Real bacon: swap the bacon bits for 4 slices of crumbled cooked bacon.
- Fresh heat: use a jalapeño or serrano pepper in place of the green chili peppers.
- More beer: use 1 cup of beer instead of 1/2 cup; a dark stout works well.
- Softer vegetables: sauté the onion and peppers in a little oil before the meat goes in.
Storage & Reheating
Refrigerate leftovers within 2 hours in shallow, covered containers and eat them within 3 to 4 days, or freeze them for 3 to 4 months. Thaw frozen chili in the fridge. Reheat on the stove, stirring, until it reaches 165°F; USDA FSIS says soups and sauces should come to a rolling boil.
What to Serve With It
Turn leftovers into Frito pie, or set out a pot of white queso dip with chips while the chili simmers. If you’re feeding a crowd all season, rotate it with Wendy’s chili, cowboy stew and quick and easy taco soup. Got beer left over? Use it in a slow cooker 3-ingredient dark beer beef roast.
Frequently Asked Questions
Can I make it in a slow cooker?
Yes. Brown the chuck and sausage on the stove and drain them first, then move everything to the slow cooker and cook on low for 6 to 8 hours.
Can I make it without beer?
Yes. Use 1/2 cup chicken broth in place of the beer.
What toppings go on boilermaker chili?
Corn chips and shredded cheddar go on every bowl. Red onion, sour cream, a squeeze of lime juice, sliced green onions and a side of cornbread all fit too.
Can I use different beans?
Yes. White beans and spicy pinto beans can stand in for the chili beans.
Final Notes
Chop all the vegetables while the meat browns, so everything is ready to go in the moment you’ve drained the grease. If you make it for a game, tell me in the comments what you topped yours with.
Boilermaker Chili
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Ingredients
- 2 pounds ground chuck
- 1 pound bulk Italian sausage
- 3 cans chili beans 15 ounces each, drained
- 1 can chili beans in spicy sauce 15 ounces, not drained
- 2 cans diced tomatoes 28 ounces each, with their juice
- 1 can tomato paste 6 ounces
- 1 yellow onion large, chopped
- 3 stalks celery chopped
- 1 green bell pepper seeded and chopped
- 1 red bell pepper seeded and chopped
- 2 green chili peppers seeded and chopped
- 1 tablespoon bacon bits
- 4 beef bouillon cubes
- 1/2 cup beer
- 1/4 cup chili powder
- 1 tablespoon Worcestershire sauce
- 1 tablespoon minced garlic
- 1 tablespoon dried oregano
- 2 teaspoons ground cumin
- 2 teaspoons hot pepper sauce
- 1 teaspoon dried basil
- 1 teaspoon salt
- 1 teaspoon ground black pepper
- 1 teaspoon cayenne pepper
- 1 teaspoon paprika
- 1 teaspoon white sugar
- 1 bag corn chips 10 1/2 ounces, such as Fritos, for serving
- 1 package shredded cheddar cheese 8 ounces, for serving
Instructions
- Heat a large stock pot over medium-high heat. Crumble the ground chuck and the sausage into the hot pan and cook until evenly browned and the beef reaches 160°F. Drain off the excess grease.
- Pour in the chili beans, the spicy chili beans, the diced tomatoes and the tomato paste. Add the onion, celery, green and red bell peppers, chili peppers, bacon bits, bouillon and beer. Season with the chili powder, Worcestershire sauce, garlic, oregano, cumin, hot pepper sauce, basil, salt, pepper, cayenne, paprika and sugar. Stir to blend.
- Cover and simmer over low heat for at least 2 hours, stirring occasionally.
- After 2 hours, taste and adjust the salt, pepper and chili powder if needed. Take it off the heat and serve, or refrigerate and serve the next day.
- Ladle into bowls and top with corn chips and shredded cheddar.
Notes
Nutrition
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