Costco Spicy Chicken Sandwich – Copycat Recipe

1 hr
1 hr
Let’s learn how to make Costco’s new Spicy Chicken Sandwich at home and even better! It starts off with a homemade cheese bun and is finished off with crispy fried chicken and a delicious spicy mayo.
Jump To Recipe

Costco Spicy Chicken Sandwich – Copycat Recipe

Let’s learn how to make Costco’s new Spicy Chicken Sandwich at home and even better! It starts off with a homemade cheese bun and is finished off with crispy fried chicken and a delicious spicy mayo.

Making the Fried Chicken

There is no spicy chicken sandwich without an extra crispy and flavorful piece of fried chicken! It’s the star of the sandwich so let’s make it perfect.

For this recipe, you’ll make a dry and wet batter. The same spices and measurements go in to both the dry and wet for extra flavor. The spicy flavor in the sandwich only comes from the spicy mayo but if you’d like to add cayenne powder to the batter for the chicken as well, feel free! Now a lot of fried chicken spots dip their chicken in the wet and then the dry first which I followed for this and it turned out great! BUT what I like even more is brining my chicken in pickle juice and milk for a few hours. Then pat the chicken completely dry! Coat in the spiced flour, then the buttermilk mixture and then the spiced flour again. I find when I coat in dry first, the breading holds on a lot better. If you have that issue a lot, try that method.

Tips For Frying Chicken

  • Make sure the oil is hot enough before frying. If it is not hot enough, the breading will soak all the oil and be mushy instead of crispy. The temperature should be right at 350°F. Do not go higher or the outside will burn before the inside has a chance to cook. If you find that your chicken is not done in the center but the outside is already golden brown, just pop it in the oven at 350F to bake until cooked through.
  • Use an oil suitable for hot temperatures like vegetable, canola, or peanut oil.
  • When breading the chicken, make sure to pat it down firmly to make sure it adheres well. This will prevent it from falling off in the fryer.
  • When dredging your chicken, make sure to let any excess wet mixture fall off before coating in the dry. If you don’t let the buttermilk drip off, it will fall off after you add the dry and you’re left with a breading that won’t stick on after frying.

Making the Cheese Bread

The best part about the Costco Spicy Chicken Sandwich is the cheese bun! So much better than a traditional sandwich or hamburger bun. It has a crispy cheese layer on top but it’s so fluffy and soft on the inside – the best of both worlds. Costco sells these buns in store and they’re so popular for a reason. Now you can make them at home and even better.

  • The dough starts off by proofing the active dry yeast. If you only have instant yeast, it does not need to be proofed.
  • The dough has cheddar cheese and parmesan mixed inside as well as on the top for double the flavor! I like the taste of medium cheddar but you can also use mild or sharp.
  • If you don’t have all purpose flour, you can use bread flour! Either works great.
  • You may need an additional 1 to 2 tablespoons of flour or milk. The dough should not be to sticky but it should be soft and moist. Add either as needed.
  • You can also brush the bread with an egg wash but I used milk!

After baking in the oven, it will be golden brown and beautiful like below. If you are not using all the buns for sandwiches and have leftovers, wraps them well and it can be kept at room temperature for a few days. Freeze for longer storage.

You may also like:

If you have any questions about this recipe, let me know in the comments! If you make this recipe, send me a picture on Instagram! I love seeing your remakes SO much.

To see a full video tutorial step-by-step of this remake, click here and don’t forget to subscribe for more recipes.

Costco Spicy Chicken Sandwich – Copycat Recipe

Let's learn how to make Costco's new Spicy Chicken Sandwich at home and even better! It starts off with a homemade cheese bun and is finished off with crispy fried chicken and a delicious spicy mayo.

Let's learn how to make Costco's new Spicy Chicken Sandwich at home and even better! It starts off with a homemade cheese bun and is finished off with crispy fried chicken and a delicious spicy mayo.

1 hr
1 hr

Ingredients

CHEESE BUNS
  • 1/4 cup whole milk warm
  • 2 teaspoons active dry yeast
  • 1/2 tablespoon sugar
  • 3 cups all purpose flour
  • 1 1/4 teaspoon salt
  • 1 1/2 tablespoon sugar
  • 1 1/4 cup shredded medium cheddar
  • 1/3 cup grated parmesan
  • 1 large egg whisked
  • 3/4 cup whole milk warm
  • 2 tablespoons butter melted
  • 2 tablespoons whole milk for brushing the top
  • 1 cup medium shredded medium cheddar to add on top
  • 1/3 cup grated parmesan to add on top
FRIED CHICKEN
  • 3 large chicken breasts pounded and cut in half
  • vegetable oil for frying
WET BATTER
  • 1 cup buttermilk
  • 1 tablespoon yellow mustard
  • 1 1/2 tablespoon chili powder
  • 1 teaspoon salt
  • 1 teaspoon garlic powder
  • 1 teaspoon smoked paprika
  • 1/2 teaspoon black pepper
  • 1/2 teaspoon onion powder
  • 1/2 teaspoon oregano
DRY BATTER
  • 1 cup flour
  • 1/2 cup cornstarch
  • 1 1/2 tablespoon chili powder
  • 1 teaspoon dry mustard powder
  • 1 teaspoon salt
  • 1 teaspoon garlic powder
  • 1 teaspoon smoked paprika
  • 1/2 teaspoon black pepper
  • 1/2 teaspoon onion powder
  • 1/2 teaspoon oregano
SPICY MAYO
  • 1 cup mayonnaise
  • 3 to 4 tablespoons hot sauce more or less to taste
  • 2 teaspoons chili powder
  • 1 teaspoon smoked paprika
  • 1/2 teaspoon garlic powder
  • cayenne powder to taste if you want it very spicy
OTHER
  • dill pickle slices
  • butter or mayo for toasting bread
  • shredded lettuce optional

Instructions

TO MAKE THE SPICY MAYO
  1. In a small bowl, combine mayo, hot sauce, chili powder, and garlic powder until smooth to make the spicy mayo.
TO MAKE THE CHEESE BUNS
  1. Add 1/4 cup of warm milk along with the yeast and sugar to a small bowl. Mix and cover for 5 to 10 minutes or until bubbly.
  2. To a large mixing bowl, add the flour, salt, the rest of the sugar, shredded cheddar, and grated parmesan. Mix together with a rubber spatula.
  3. Then add in the whisked egg, warm milk, melted butter, and the proofed yeast mixture.
  4. Use the dough hook attachment to combine together and knead the dough for about 5 minutes. You can also knead by hand. The dough should not be sticky but also should not be dry. Add a tablespoon of milk or tablespoon of flour if you need to adjust.
  5. Cover the dough in large bowl with saran wrap and a warm damp towel and place in a warm place to double in size - about 1 to 2 hours.
  6. Uncover and roll into a large rectangle. Cut into about 8 square/rectangle pieces. If you prefer a round shape, split the dough into 8 equal pieces and roll into a bowl.
  7. Place on a parchment-lined tray and cover again in a warm spot until double in size - about another hour.
  8. Preheat oven to 375°F.
  9. Brush the tops of the buns with milk and sprinkle the top with cheddar and parmesan.
  10. Bake for 22 to 25 minutes or until the top is golden brown and crispy and the center is cooked through.
TO MAKE THE FRIED CHICKEN
  1. In a deep bowl, add the buttermilk, yellow mustard, chili powder, salt, garlic powder, smoked paprika, black pepper, onion powder, and oregano. Whisk together. Add the chicken filets in to the spiced buttermilk and cover. Let it sit for 30 minutes to an hour. The longer the better!
  2. In a shallow and wide bowl, add flour, cornstarch, mustard powder, chili powder, salt, garlic powder, smoked paprika, black pepper, onion powder, and oregano. Whisk and set aside.
  3. Add 3 tablespoons of the wet batter into the dry and mix around to create a flaky texture.
  4. Take the chicken out of the wet and allow excess to drip off. Then transfer to dry and use the other hand to bread the chicken. Pat it well and shake off any excess flour. Transfer to a plate to rest for 10 minutes after breading all the chicken.
  5. Heat oil to about 350°F in a frying pan. Drop one filet at a time, making sure not to overcrowd them. Fry in 2 batches if needed. Fry until golden brown all around, about 7-8 minutes. Make sure to rotate them around as needed for even browning but don't bother them too much. Transfer to a wired tray to let any excess oil drip off.
ASSEMBLY
  1. Cut the buns open in half and spread butter or mayo on each side and toast on a pan until golden. Add spicy mayo to both sides. Then add pickles to the bottom bun, the chicken, and close with the top bun. Enjoy warm.

WHAT DO YOU THINK OF THIS RECIPE?

Rate + Review

Pin This Recipe