Leftover Smoked Ham & Swiss Sliders on the Traeger (with Chipotle Aioli)

If you’re staring at leftover ham and thinking, there has to be a better way than another cold sandwich, you’re in the right place. These Ham & Swiss sliders take everything you already love and level it up with buttery King’s Hawaiian bread, melty Swiss, and a subtle kiss of smoke from the Traeger. They’re warm, rich, a little indulgent, and the kind of food that disappears faster than you planned.

In this recipe, I’ll show you:

• How to turn leftover ham into sliders people actually hover over
• A quick chipotle aioli made with Duke’s that adds just the right bite
• Why toasting the King’s Hawaiian loaf on the Traeger Flatrock changes everything
• How finishing on the Timberline XL melts the cheese and locks in flavor with light smoke

Nothing fancy. No unnecessary steps. Just a smart, repeatable way to make leftover ham taste like the main event.

Let’s get started!

Why You’ll Want to Make These

This recipe is all about taking simple ingredients and giving them just enough attention to feel special. Sweet Hawaiian bread, salty ham, nutty Swiss, and a little heat from the aioli hit that perfect comfort-food balance. Toasting the bread first keeps everything crisp, and the pellet grill finish pulls it all together.

Here’s why these sliders work so well:

• They’re the best way I know to use up leftover ham
• Easy to scale up for game day, parties, or feeding a crowd
• The Traeger adds flavor without drying anything out

Ingredients

Sandwiches

• Leftover ham slices
• King’s Hawaiian slider loaf
• Swiss cheese slices
• Butter, melted

Sauce & Seasoning

• Duke’s Mayonnaise
• Duke’s Chipotle Mustard
• Rock’s Hey Boo! Honey Rub
• Rock’s Anytime Seasoning

Best Wood Pellets for This Recipe

• Signature Blend – Balanced and versatile, hard to go wrong
• Meat Church Blend – Strong oak presence that plays nicely with coffee
• Hickory – Bold, classic smoke if you like traditional jerky flavor

Step 1: Make the Chipotle Aioli (About 5 minutes)

• In a small bowl, mix Duke’s Mayonnaise, Duke’s Chipotle Mustard, & Rock’s Hey Boo! Honey Rub
• Start with about two parts mayo to one part mustard, and two tablespoons of Rock’s Honey Rub
• Taste it and adjust if you want more heat or creaminess
• Set it aside while you build the sliders

Step 2: Toast on the Traeger Flatrock (8–10 minutes)

• Preheat the Flatrock to medium heat
• Slice the King’s Hawaiian loaf in half horizontally, keeping the rolls connected
• Brush the loaf lightly with melted butter
• Place the sliders cut-side down and toast until golden and crisp

This step is what keeps the sliders from getting soggy later, so don’t skip it.

Step 3: Build the Sliders (10 minutes)

• Start with a layer of Swiss cheese on the toasted buns
• Layer the ham across, edge to edge, overlapping into a couple of layers
• Spread the chipotle aioli evenly on the ham
• Layer on another layer of Swiss Cheese
• Place the top half of the loaf back on
• Brush the tops with more melted butter
• Sprinkle lightly with Rock’s Anytime Seasoning

Step 4: Finish on the Traeger Timberline XL (15–20 minutes)

• Preheat the Timberline XL to 350°F
• Transfer the sliders to a pan or baking sheet
• Cook until the Swiss is fully melted and everything is warmed through
• Cut into individual sandwiches and serve!

Key Steps, Quick Version

• Mix up the chipotle aioli
• Toast the loaf on the Flatrock for crunch
• Build the sliders with ham and Swiss
• Finish on the Timberline XL for melt and smoke
• Slice and serve while hot

Pro Tips

• Don’t overstack the ham. Even layers melt better and slice cleaner
• Toasting first is the secret. It gives you texture that holds up on the grill
• Let the sliders rest for a couple minutes before cutting so the cheese doesn’t slide out

Common Questions

Can I prep these ahead of time?
Yep. Assemble them earlier in the day, wrap tightly, and toast and finish when you’re ready to eat.

What if I don’t have leftover ham?
Deli-sliced ham works just fine. Fold it instead of stacking it flat.

Can I swap the cheese?
Absolutely. American or provolone are both solid options.

Do I really need both Traegers?
Using both gives you the best result, but you can toast in a skillet and still finish on the Timberline if needed.

Final Thoughts

These Ham & Swiss sliders are the kind of recipe that sneaks up on you. Buttery, melty, just a little smoky, and gone way faster than anyone expects. What started as “using up leftover ham” turns into people grabbing seconds and asking when you’re making them again.

If this is what leftovers can do, there’s a whole lot more where that came from. Stick around, because this is exactly how simple ingredients turn into backyard favorites.

Ready to try it?