I firmly believe one grilled cheese is never enough.
A single plain grilled cheese — bread, melty cheese, maybe a side of pickles — rarely satisfies me. Usually I want another, or at least most of one. I’ve shared photos of my drippy, crunchy sandwiches on social media for years. This version brings that obsession to the sandwich itself.
If a plain grilled cheese won’t cut it, stuff it. Add crunchy, well-seasoned elements and a bright, tangy aioli to elevate the sandwich into something unforgettable.
Fried zucchini has been an appetizer staple in my family since forever. Sometimes it’s perfect, sometimes it tastes like everything else that’s been in the fryer for days. My mom used to make skillet “fried” zucchini in summer using a few tablespoons of oil in a cast iron pan, cooking the slices until they were golden and coating them generously in parmesan. That simple, crispy approach is where I learned to love zucchini in sandwiches.
I almost called this “fried zucchini grilled cheese,” but if that phrase makes you throw your hands up, know this: you can bake the zucchini on a wire rack for a lighter approach or pan-fry it in a bit of olive oil for extra crispiness. Use whole grain bread if you like — then feel no guilt, because it’s practically health food.
What matters is texture and flavor: crunchy, cheesy zucchini rounds layered with melty cheddar and a mustard-horseradish aioli. The aioli cuts through the richness and brings a bright, savory tang that makes every bite sing. Whether you bake or fry the zucchini, assemble and toast the sandwich slowly so the cheese melts and the bread toasts to a perfect golden brown.
Crispy Zucchini Grilled Cheese with Dijon Horseradish Aioli
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Ingredients
- 4 slices whole grain bread
- 1 small zucchini, sliced into 1/4-inch rounds
- 1 large egg + 1 large egg white
- 3/4 cup panko bread crumbs
- 1/3 cup seasoned fine bread crumbs
- 1/4 cup flour
- 1/4 cup finely grated parmesan cheese
- 1/2 teaspoon salt
- 1/2 teaspoon pepper
- 1/2 teaspoon garlic powder
- 2 tablespoons olive oil
- 6 ounces freshly grated cheddar cheese
- softened butter for spreading
aioli
- 1 1/2 tablespoons dijon mustard
- 1 large egg yolk
- 2 teaspoons fresh lemon juice
- 1/2 cup olive oil
- 2 tablespoons whole grain mustard
- 1 1/2 tablespoons prepared horseradish
- a pinch of salt and pepper
Instructions
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Prep the aioli first (recipe below).
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In a bowl, whisk together the egg and egg white. In another bowl, combine the panko, breadcrumbs, flour, parmesan, salt, pepper and garlic powder. Heat a large skillet over medium and add olive oil. Dip each zucchini slice in the egg mixture, then dredge in the breadcrumb mixture, pressing gently to adhere. Cook in the skillet until golden, about 2 minutes per side. Transfer to paper towels to drain.
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Spread one side of each bread slice with softened butter. Heat a skillet over medium (wipe out the skillet used for zucchini if desired). Place bread buttered-side down, top with a spoonful of aioli, a handful of grated cheese, a few zucchini slices, more cheese and more aioli. Top with the second slice of bread, buttered-side up. Cook until cheese melts and bread is golden brown, about 5 minutes per side; lower heat if the bread browns too quickly. Serve immediately and dip any extra zucchini in remaining aioli.
aioli
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Whisk dijon mustard, egg yolk and lemon juice in a bowl until combined. Slowly stream in olive oil while whisking constantly until the mixture emulsifies. Stir in whole grain mustard and horseradish, then season with salt and pepper to taste. Set aside.
Notes
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This sandwich is absolutely worth the effort.