Pepper Jack Zucchini Sandwich Stacks

Pepper jack zucchini sandwich stacks use crunchy fried zucchini slices as the bread, with melted cheese and pickled jalapenos tucked between them. If you enjoy breaded zucchini and a little heat, this recipe brings both together with spicy mayo for dipping. The recipe takes 40 minutes and serves 4.

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Ingredients for pepper jack zucchini sandwich stacks

• 2 large zucchini
• 1 1/2 tsp salt, divided
• 1/2 cup all purpose flour
• 2 large eggs, beaten
• 1 1/2 cups fine dry breadcrumbs
• 1/2 tsp black pepper
• Vegetable oil for frying
• 6 slices pepper jack, cut to fit
• 12 pickled jalapeno slices
• 1/2 cup mayonnaise
• 1 tbsp hot sauce

Dry the zucchini before breading

The first place to pay attention is the surface of the zucchini. After cutting it lengthwise into 12 slices, each 1/4 inch thick, sprinkle it with 1 tsp salt and wait 15 minutes. Moisture on the outside can make the coating harder to apply evenly, so pat the slices very dry before reaching for the flour.

Keep track of the divided salt as you work. The remaining salt belongs in the breadcrumbs with the black pepper. Mixing that seasoning through the crumbs distributes it across the coating instead of leaving concentrated patches on individual slices.

Have the filling ready before frying

Cut the pepper jack to fit the zucchini and have the pickled jalapeno slices ready to place. The filling goes onto the zucchini while it is hot, so this is a useful task to finish before the frying begins. Stir the mayonnaise and hot sauce together and chill the sauce as directed.

Each stack gets cheese and 2 jalapeno slices between the breaded zucchini pieces. Place the filling within the edges so the top slice can sit against it. The cheese needs contact with the hot zucchini to soften and help hold the sandwich together.

Coat, fry, and assemble the stacks

• Cut the zucchini lengthwise into 12 slices, 1/4 inch thick. Sprinkle with 1 tsp salt, wait 15 minutes, and pat very dry.
• Stir the mayonnaise and hot sauce together in a small bowl. Chill until serving.
• Mix the fine dry breadcrumbs with the black pepper and remaining salt. Coat each zucchini slice in flour, then beaten egg, then the seasoned crumbs.
• Heat 1/4 inch of vegetable oil to 350°F. Fry the coated zucchini in batches for 2 to 3 minutes per side, until golden.
• While the slices are hot, lay pepper jack and 2 pickled jalapeno slices on one zucchini slice. Press a second zucchini slice on top.
• Rest for 1 minute so the cheese melts and holds the stack together. Serve with the spicy mayo.

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Watch the coating as you work

The flour, egg, and breadcrumb order gives each coating layer something to cling to. Cover the broad faces and the edges as you move through the breading. Bare areas will look different from the surrounding golden crust, so check each slice before it goes into the oil.

Use the stated oil temperature and fry in batches. Look for a golden coating on each side within the recipe’s 2 to 3 minutes per side. The lengthwise slices need attention when you turn them, since keeping the crust intact makes assembly easier.

Build each stack straight from the pan. Waiting until all the zucchini has cooled takes away the heat needed to melt the pepper jack. Once the second slice is pressed into place, give the stack its 1 minute rest before serving.

Serve with the spicy mayo alongside

Keep the spicy mayo alongside the stacks so you can dip the crisp edges as you eat. The sauce combines mayonnaise and hot sauce, while the filling carries the pepper jack and pickled jalapenos. Serving the sauce separately also leaves the golden coating visible.

This recipe is written for serving after assembly and the brief rest. It does not provide storage or reheating instructions, so plan the frying around when you intend to serve the stacks.

For more zucchini recipes, try crispy fried zucchini sandwich stacks , cheesy fried zucchini planks with marinara , or Parmesan fried zucchini planks with garlic aioli .

Questions about the coating and filling

Are these stacks very spicy?

The heat comes from pepper jack, pickled jalapenos, and the hot sauce in the mayo. The recipe does not specify a hot sauce variety, so the sauce you use will affect how hot the dip tastes.

Does this recipe use a wet batter?

No. The zucchini gets separate layers of flour, beaten egg, and seasoned fine dry breadcrumbs. Keep those coating stages separate when preparing the slices.

Why is the cheese still firm after assembly?

The zucchini may have lost too much heat before the filling went in. The recipe specifically calls for building straight from the pan, then resting so the pepper jack can melt and hold.

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Written and edited by The Foodie Yummy Kitchen Team

The Foodie Yummy Kitchen Team writes and edits the recipes on Foodie Yummy: classic American potluck salads, holiday sides and easy comfort food, with a few low-carb options. Every recipe lists exact quantities, numbered steps and a printable recipe card, plus notes on swaps, storage and make-ahead timing. Spot a problem with a recipe? Tell us through the contact page and we will correct it. About us