Potatoes are seasoned and smoked on the grill to soften them up, before the interior of the potato is removed with a melon baller and mixed with cheese, sour cream and green onions. That potato mixture is mashed up and piped back into the potatoes before they are wrapped in bacon. The potatoes go back on the grill to make these Grilled Bacon-Wrapped Potato Volcanos into twice baked potatoes. 

I’ll admit, I haven’t done a great job adding side dish options to the website lately. It weighted on my mind lately and when I saw a recipe for potato volcanos I had to do my version. See, I LOVE baked potatoes with all the fixin’s, and love them even more when they are smoked on the grill, whether as hasselback potatos or not. 

Grilled bacon-wrapped potato volcanoes Ingredients:

  • 6 Potatoes (russet and Yukon gold’s work very well) – 7 potatoes shown
  • Olive oil
  • Granulated garlic (or garlic powder)
  • Bourbon smoked sea salt (substitute any coarse salt, if it’s flavored, even better)
  • Melon baller
  • 1 cup sour cream
  • 1 cup shredded cheddar cheese (we prefer fresh grated)
  • 2 sticks (half pound) softened salted butter
  • 1 cup whole milk (for extra juicy potatoes like these, drop to 1/2 cup)
  • 1 tbsp favorite barbecue rub
  • Potato pulp – will be obtained after first cook
  • 1 gallon zipper bag
  • 6 slices of bacon
  • Toothpicks to secure the bacon
  • 6 slices of cheddar cheese
  • 4 green onions, sliced

How to Prepare Grilled Bacon-Wrapped Potato Volcanos

Start by washing the potatoes and poking holes in each one multiple times with a fork:

In the ingredients I recommend to cut down on the milk in the recipe by half if the potatoes you use are extra juicy. I’ve done this fork thing on hundreds of potatoes. Never have I had this much liquid come out:

Once the spuds are rinsed and poked, it’s time to drizzle some olive oil over the taters so place them on a platter or a rimmed cookie sheet because we are going to use a good amount of oil here:

Next up, the seasoning.

Try some flavored salts

I used a bourbon smoked salt, but any coarse salt will work. Garlic infused smoked salt would be fantastic too:

Always oil the taters first

Once the oil has been drizzled all over potatoes we have something for the seasoning to stick to. Season with the coarse salt first:

Because the granulated garlic/garlic powder is so fine, if you put it on first, it will completely coat the potatoes and not leave much for the salt to stick to, so always go with the salt first, followed by the garlic:

Here are our seasoned spuds:

These taters are only seasoned on the one side, so flip them over and repeat the process:

How to Make Grilled Bacon-Wrapped Potato Volcanoes

Now, prepare the grill for two zone or indirect grilling with coals on one side and nothing on the other. The target temp inside of the grill is between 350F-425F:

You can place the potatoes directly on the grill grates or on a cookie sheet lined with foil as we did here:

Place a chunk of mild smoke wood on the coals and close the lid. Let the heat and smoke work their magic. 

Also, don’t throw away the oil and seasoning mixture that are on the platter or cookie sheet used to oil and season the potatoes. More on that in a little while.

After an hour, the potatoes have darkened up but still have a ways to go:

We need these potatoes to soften up. These took 2.5 hours at approximately 360-375F because these Yukon golds are really thick. Russets are thinner and don’t take nearly as long, but we sourced ours through the farmers market and the Russets weren’t in season yet. Actually, we prefer russets as the skin gets crispier than the Yukons

After the potatoes had been on for about 90 minutes, it’s time to make use of that seasoned oil:

Don’t dump this ticket to Flavortown. Drizzle the flavored oil over the potatoes midway through the cook:

Close the lid and let the potatoes keep baking/smoking.

When they are good and soft they are usually brown too:

More Potato Prep

I would recommend putting these straight into the fridge for about 30 minutes or you’re risking playing hot potato with these lava spuds. Once they’ve cooled enough to handle, slice off the ends of the potatoes:

Oh, did I forget to mention that our Grilled Bacon-Wrapped Potato Volcanos are a twice baked potato? I did? Oh, sorry. 

Then, get the melon baller and scoop out a bunch of the potato pulp in the middle, making sure not to go too close to the wall of the potato or too close to the bottom:

Create the volcano filling

Next, dump all of the potato pulp into a large mixing bowl and add the butter, sour cream, milk and shredded cheese:

Use a spatula to fold all the ingredients together and then grab the potato masher:

If the potato mixture is too thin, add the ends of the potatoes we cut off. It’s OK if it is a little thin because the goal is to dump all of that into a gallon zipper bag. Then, cut off the corner of the bag creating a large homemade piping bag to pipe the concoction into the potatoes. Indeed, I can’t recommend this enough. It saved us a TON of time:

Then, bust out that bacon:

One slice of bacon should do it for the shorter, stouter Yukon Gold’s. For the longer, skinnier, Russet’s, two slices will be needed:

Grilled Bacon-Wrapped Potato Volcanos

Next, place the Grilled Bacon-Wrapped Potato Volcanos back on the foil-wrapped cookie sheet:

Grilled Bacon-Wrapped Potato Volcanos

Now time to get back on the grill

Grilled Bacon-Wrapped Potato Volcanos

Once the bacon browns up a bit, it’s time to add the cheese which will complete our smoked potato volcanoes:

Grilled Bacon-Wrapped Potato Volcanos

I put on a slice and a half of cheese on the Grilled Bacon-Wrapped Potato Volcanos, but felt like it was a bit too much cheese so I would suggest just one slice:

Grilled Bacon-Wrapped Potato Volcanos

Close the lid and once the cheese melts, the bacon wrapped potatoes with cheese are done (make sure to dice your green onions while that cheese melts):

Grilled Bacon-Wrapped Potato Volcanos

Sprinkle with the green onions and serve:

Slice the BBQ volcano potatoes in half to make one batch feed twice as many:

Grilled Bacon-Wrapped Potato Volcanos

Grilled bacon-wrapped potato volcanos run down:

The garlicky, salty outer potato skins marry so well with warm and creamy inner potato, which is all enveloped in either wonderful bacon, melty cheese, or both. This dish may take some time to prepare, but it is soooo worth it!

Did I mention that the potatoes and the stuffing can be prepared the night before and finished up on the grill the next day to save some time?

If you have any questions about these Grilled Bacon-Wrapped Potato Volcanos, feel free to leave them below or shoot me an email

Additionally, if you could leave us a great review that would be most appreciated!

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Grilled Bacon-Wrapped Potato Volcanos

Twice smoked potatoes, wrapped in bacon and topped with cheese and green onions otherwise known as Grilled Bacon Wrapped Potato Volcanos
Prep Time20 minutes
Cook Time3 hours
Total Time3 hours 20 minutes
Course: Baked Potato, Side Dish
Cuisine: American, American Fare, Baked Potatoes, Grilling
Keyword: Bacon, Bacon Wrapped, Bacon Wrapped Potatoes, Baked Potatoes, Potato Volcanos, Side Dish, Spuds, Taters, Twice Baked Potatoes
Servings: 8 People


  • melon baller
  • 1 gallon zipper bag
  • 6 toothpicks


  • 6 potato (russet and Yukon gold's work very well)
  • olive oil
  • Granulated garlic or garlic powder
  • Bourbon smoked sea salt (substitute any coarse salt, if it's flavored, even better)
  • 1 cup sour cream
  • 1 cup cheddar cheese shredded (we prefer fresh grated)
  • ½ lb salted butter (2 sticks), softened
  • 1 cup whole milk (for extra juicy potatoes like these, drop to 1/2 cup)
  • 1 tbsp your favorite BBQ rub
  • potato pulp (will be obtained after first cook)
  • 6 slice Farmland Applewood Smoked Classic Cut Bacon
  • 6 slice cheddar cheese
  • 4 green onion sliced


  • Wash the potatoes and poke deep holes all the way around each spud with a fork
  • Place the potatoes on a platter or a rimmed cookie sheet and drizzle with olive oil before sprinkling with salt and the garlic
  • Flip the potatoes over and repeat the process
  • Prepare the grill for two zone or indirect grilling with charcoal on one side and nothing on the other
  • Place the potatoes on a foil lined cookie sheet and put them on the side with no heat and drop a chunk of mild smoke wood on the coals
  • Close the lid
  • After 60 minutes for russets or 90 minutes for these Yukon Gold's, drizzle the seasoned olive oil from the platter over the potatoes
  • Keep smoking until the potatoes are soft
  • Remove them from the grill and place them in the fridge for 30 minutes
  • Slice the end off the potatoes and then core them out with a melon baller making sure not to go too close to the sides or the bottom
  • Place the potato pulp in a mixing bowl and add the butter, milk, grated cheese and BBQ rub
  • Using a spatula, fold the ingredients together and then mash with a potato masher
  • Pour the ingredients into a gallon zipper bag
  • Cut off the corner and pipe the stuffing mixture into the cored out potatoes
  • Wrap with a slice of bacon and affix in place with a toothpick
  • Put the potatoes back on the grill until the bacon browns a bit
  • Place a folded up slice of cheddar on top of each and close the lid
  • While the cheese melts, chop the green onions for garnish
  • Once the cheese melts place each potato on a plate (or cut in half and double the number served) and sprinkle with the sliced green onions

More pics of the grilled bacon-wrapped potato volcanos process

Grilled Bacon-Wrapped Potato Volcanos

Grilled Bacon-Wrapped Potato Volcanos





Scott Thomas

Scott Thomas

Scott Thomas, the Original Grillin’ Fool, was sent off to college with a suitcase and a grill where he overcooked, undercooked and burned every piece of meat he could find. After thousands of failures, and quite a few successes, nearly two decades later he started a website to show step by step, picture by picture, foolproof instructions on how to make great things out of doors so that others don’t have to repeat the mistakes he’s made on the grill.
Scott Thomas

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