Grilled Cheese Sausage and Egg Breakfast Casserole (Print Version)

A hearty breakfast casserole made with buttery grilled-cheese pieces, browned sausage, fluffy eggs, and plenty of melted cheddar.

# Ingredients:

→ For the sausage

01 - 1 lb (450 g) pork breakfast sausage
02 - 1 small yellow onion, finely diced

→ For the grilled-cheese bread

03 - 12 slices sturdy sandwich bread or sourdough sandwich bread
04 - 4 tablespoons (56 g) unsalted butter, softened
05 - 2 1/2 cups (280 g) shredded sharp cheddar cheese, divided
06 - 1 cup (115 g) shredded mozzarella cheese

→ For the egg custard

07 - 12 large eggs
08 - 2 cups (480 ml) whole milk
09 - 1 tablespoon Dijon mustard
10 - 1 teaspoon kosher salt
11 - 1/2 teaspoon black pepper
12 - 1/2 teaspoon garlic powder
13 - 2 tablespoons chopped fresh chives, plus more for serving

# Instructions:

01 - Heat the oven to 425°F. Butter or spray a 9x13-inch baking dish and set it aside.
02 - Cook the sausage and onion in a large skillet over medium-high heat for 8-10 minutes, breaking the meat into crumbles, until browned and cooked through. Drain excess fat.
03 - Butter one side of each bread slice. Arrange 6 slices butter-side down on a baking sheet, top with 1 1/2 cups cheddar and the mozzarella, then cover with the remaining bread butter-side up. Bake for 8-10 minutes, turning once if needed, until golden and melted.
04 - Let the grilled-cheese sandwiches cool for 5 minutes. Cut them into 1-inch pieces. Reduce the oven temperature to 350°F.
05 - In a large bowl, whisk the eggs, milk, Dijon, salt, pepper, garlic powder, and chives until evenly blended.
06 - Scatter half the grilled-cheese pieces in the prepared dish. Add the sausage mixture, sprinkle with the remaining 1 cup cheddar, and top with the remaining grilled-cheese pieces. Pour the custard evenly over the top and press gently. Let stand for 10 minutes.
07 - Cover with foil and bake for 25 minutes. Uncover and bake 20-25 minutes more, until the top is golden and the center reaches 165°F. Rest for 10 minutes before slicing.

# Notes:

01 - Best served warm after a 10-minute rest.
02 - Assemble up to 24 hours ahead and refrigerate before baking.
03 - Use a thermometer in the center of the casserole for doneness.

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