
Few things bring people to the breakfast table faster than the smell of buttery grilled cheese and hearty sausage. This Grilled Cheese Sausage and Egg Breakfast Casserole is comfort food designed for easy mornings and big appetites perfect for holidays or weekends when you are feeding a crowd and want something truly special but surprisingly simple to make.
My family thinks this tastes like a breakfast sandwich and French toast had a delicious baby. Every time I serve it for a gathering there are never leftovers simply happy faces.
Ingredients
- Pork breakfast sausage: adds savoriness and protein for a filling start Sousage with a nice fat content browns beautifully and stays juicy
- Large eggs: create volume and fluffiness Fresh eggs yield best results but any large eggs work
- Butter: brings richness and toasts the bread Golden salted butter really makes the difference for flavor
- Whole milk: gives the casserole a custardy texture Whole milk yields creamy results avoid lowfat if you can
- Kosher salt: highlights all the flavors Even a pinch makes a huge difference in taste
- Coarse ground black pepper: adds just the right bite Use fresh cracked pepper for more aroma
- Ground mustard: brightens and adds a subtle tang Look for ground mustard in the spice aisle or grind your own from seeds
- Texas toast: thick slices make the perfect grilled cheese base Thick cut bread will stay soft inside and hold the filling
- American cheese: gets melty and gooey Classic choice for grilled cheese thanks to the melt factor swap with cheddar for deeper flavor
- Choose freshly sliced cheese from the deli counter for the smoothest melt
Step by Step Instructions
- Brown the Sausage:
- Crumble sausage in a large skillet over medium high heat Let it cook undisturbed for 2 minutes to start browning the edges then stir and break apart until fully browned about 4 to 5 minutes Drain the fat well for the best texture
- Make Soft Scrambled Eggs:
- In the same pan add one tablespoon of butter over medium heat Whisk 10 eggs with a quarter cup of milk plus a pinch each of salt and pepper Pour it in and gently scramble until just set and still soft This will help prevent the eggs from drying out during baking
- Build the Grilled Cheese Base:
- Butter a 9 by 13 baking dish Arrange 6 slices of Texas toast on the bottom Place a slice of American cheese on each bread slice so the cheese creates a gooey base
- Layer the Sausage and Eggs:
- Top the cheese covered bread with all the browned sausage Next evenly layer your just set scrambled eggs over the sausage Spread it in an even layer but do not press down
- Add More Cheese and Egg Custard:
- Top the eggs and sausage with another layer of cheese In a separate bowl whisk together the remaining 8 eggs three fourths cup milk and the ground mustard Pour this egg mixture evenly over the layered casserole letting it soak into the bread
- Seal the Casserole:
- Finish with the final 6 bread slices lined up on top Melt 3 tablespoons of butter and brush it over the bread for an extra golden crust
- Bake to Golden Perfection:
- Cover the pan with foil and bake at 375 F for 20 minutes This steams the casserole so it cooks through Remove the foil and bake another 20 minutes The bread should be crisp and the filling set Allow the casserole to rest for 10 minutes before slicing

I am obsessed with the combination of crispy Texas toast and melty American cheese It takes me back to childhood grilled cheese lunches but adds a whole breakfast twist My kids beg for this recipe on snow days and it always fills the house with the best smell
Storage Tips
Let leftover casserole cool completely then wrap tightly or transfer to an airtight container Store in the fridge for up to four days Individual portions reheat best in the microwave or toaster oven for a crisp top. If freezing assemble the uncooked casserole tightly wrap and freeze up to two months Thaw in the fridge overnight before baking as usual
Ingredient Substitutions
Swap Texas toast for thick slices of brioche or challah for a sweeter touch Use cheddar or Colby if American cheese is not your favorite For a lighter version try turkey sausage and reduced fat milk but the texture will be slightly less creamy
Serving Suggestions
Present with a fresh fruit salad and hot coffee for a complete brunch Add hot sauce or a pinch of smoked paprika for some kick This pairs especially well with a green salad for lunch leftovers

Cultural and Historical Context
Breakfast casseroles became popular in American kitchens for their practicality When everyone gathers for holidays or weekends big batch meals make hosting a breeze This recipe is a mashup of classic grilled cheese and the traditions of breakfast egg bakes
Frequently Asked Questions
- → Can I use a different type of bread?
Yes, you can substitute Texas toast with brioche, sourdough, or any sturdy bread for a similar structure and flavor.
- → What type of sausage works best?
Pork breakfast sausage is traditional, but turkey or plant-based sausage also work well for different preferences.
- → Can this dish be made ahead of time?
Absolutely! Assemble the casserole the night before and refrigerate. Bake fresh in the morning for convenience.
- → How should leftovers be stored?
Store leftovers in an airtight container in the refrigerator for up to 3 days. Reheat in the oven or microwave.
- → Can I add vegetables for extra flavor?
Feel free to include sautéed onions, peppers, or spinach between layers to add color, texture, and nutrients.