Perfect for 4 servings – A smoky, rich homemade sauce that beats store-bought every time
Key Points:
- Creates 2 cups of sauce – perfect for 4-6 servings of grilled meats
- Rich smoky flavor from natural hickory seasoning
- Keeps fresh for 2 weeks in the fridge
- No corn syrup or artificial ingredients
Why Make Your Own Hickory BBQ Sauce?
Store shelves are stacked with barbecue sauces, but nothing matches the taste of homemade hickory BBQ sauce. This recipe brings together sweet, tangy, and smoky flavors that work perfectly on chicken, pork, or beef. If you enjoy exploring different BBQ and grilling sauces, making your own at home gives you complete control over ingredients and flavor.
Nutrition Facts (per 1/4 cup serving)
| Nutrient | Amount |
|---|---|
| Calories | 70 |
| Total Fat | 0.5g |
| Sodium | 380mg |
| Total Carbs | 17g |
| Sugar | 15g |
| Protein | 1g |
What You’ll Need
Ingredients
| Item | Amount | Notes |
|---|---|---|
| Tomato sauce | 1 cup | Plain, unseasoned |
| Brown sugar | 1/4 cup | Light or dark both work |
| Apple cider vinegar | 2 tablespoons | Not regular vinegar |
| Worcestershire sauce | 1 tablespoon | Adds umami flavor |
| Natural hickory smoke flavoring | 1 teaspoon | Found in spice aisle |
| Mustard powder | 1 teaspoon | Also called dry mustard |
| Garlic powder | 1/2 teaspoon | Not garlic salt |
| Onion powder | 1/2 teaspoon | Not onion salt |
| Black pepper | 1/4 teaspoon | Freshly ground best |
| Salt | 1/2 teaspoon | Regular table salt |
| Paprika | 1 teaspoon | Sweet, not smoked |
Kitchen Equipment
| Tool | Purpose | Important Notes |
|---|---|---|
| Medium saucepan | Main cooking vessel | 2-3 quart size ideal |
| Measuring cups & spoons | Accurate measurements | Both dry and liquid measures |
| Whisk | Mixing ingredients | Silicon or metal both work |
| Glass jar with lid | Storage | Must be heat-safe |
| Rubber spatula | Scraping sides | Heat-resistant type |
| Timer | Track cooking time | Phone timer works too |
| Heat-safe surface | Protect counter | Trivet or pot holder |
Ingredient Substitutions
- Replace brown sugar with honey (use same amount)
- Swap tomato sauce for ketchup (reduce added sugar to 2 tablespoons)
- Use smoked paprika if hickory flavoring isn’t available (increase to 2 teaspoons)
Detailed Step-by-Step Instructions for Beginners
Before You Start (10 minutes)
- Kitchen Setup
- Clear and clean your counter space
- Place stove-safe surface near cooking area
- Ensure sink is empty for easy access
- Have a paper towel roll handy
- Ingredient Preparation
- Take all ingredients out
- Group dry ingredients together
- Group wet ingredients together
- Check expiration dates
- Let refrigerated items reach room temperature
- Equipment Setup
- Place saucepan on stove (don’t turn on yet)
- Set measuring tools nearby
- Have whisk and spatula ready
- Place storage jar away from cooking area
- Set timer within easy reach
Measuring Phase (5-7 minutes)
- Measure Wet Ingredients First
- Pour tomato sauce into liquid measuring cup
- Measure vinegar in tablespoon measure
- Measure Worcestershire sauce in tablespoon measure
- Place each in separate small bowls if desired
- Measure Dry Ingredients
- Use dry measuring cups for brown sugar
- Level each spoon measure with flat knife
- Place measured spices in small bowls if desired
- Keep salt separate (for adjusting later)
Cooking Process (20-25 minutes)
- Starting the Sauce (2-3 minutes)
- Turn stove to medium heat
- Pour tomato sauce into pan
- Stir gently with whisk
- Watch for first bubbles
- Adding Dry Ingredients (3-4 minutes)
- Add brown sugar first
- Sprinkle slowly while whisking
- Make sure it dissolves completely
- Add spices one at a time
- Whisk after each addition
- Break up any clumps you see
- Add brown sugar first
- Adding Wet Ingredients (2-3 minutes)
- Pour vinegar slowly while whisking
- Add Worcestershire sauce
- Add hickory flavoring last
- Whisk until everything looks uniform
- Simmering Stage (15-20 minutes)
- Wait for first bubbles
- Reduce heat to low
- Sauce should barely bubble
- Stir every 2-3 minutes
- Watch for thickening
- Test thickness by coating spoon
- Sauce should leave clear line when you run finger across spoon
Finishing Steps (10 minutes)
- Final Adjustments
- Turn off heat
- Let stand 2 minutes
- Taste carefully (it’s hot!)
- Add salt if needed
- Stir in any final adjustments
- Cooling Process
- Leave in pan 5 minutes
- Stir occasionally
- Look for steam to reduce
- Storage Preparation
- Check jar is completely clean
- Ensure lid fits properly
- Have funnel ready if using
- Transferring Sauce
- Use funnel if needed
- Pour slowly
- Scrape sides with spatula
- Leave 1/2 inch space at top
- Wipe jar rim clean
- Seal tightly
Common Problems & Solutions
- Too Thin:
- Simmer longer, 5 minutes at a time
- Check thickness with spoon test
- Never raise heat to speed up process
- Too Thick:
- Add water, 1 tablespoon at a time
- Whisk well after each addition
- Return to simmer briefly
- Too Sweet:
- Add vinegar, 1/2 teaspoon at a time
- Mix completely before tasting
- Wait 1 minute between additions
- Too Tangy:
- Add brown sugar, 1 teaspoon at a time
- Ensure sugar dissolves completely
- Mix well between additions
- Not Smoky Enough:
- Add hickory flavoring, 1/4 teaspoon at a time
- Mix thoroughly
- Wait 2 minutes before tasting
Recipe Variations
- Spicy Version:
- Add 1/2 teaspoon cayenne pepper
- Start with 1/4 teaspoon if unsure
- Can add hot sauce instead
- Sweet & Smoky:
- Double brown sugar amount
- Add extra 1/2 teaspoon hickory
- Cook 5 minutes longer
- Extra Tangy:
- Increase vinegar to 3 tablespoons
- Reduce sugar slightly
- Add 1 teaspoon lemon juice
- Honey Hickory:
- Replace brown sugar with honey
- Use 3 tablespoons for perfect sweetness
- For more ideas, check out my honey barbecue sauce recipe that pairs beautifully with this hickory version
Storage Guide
- Refrigerator:
- Keeps 2 weeks
- Store in airtight container
- Keep in back of fridge
- Mark date on container
- Freezer:
- Up to 3 months
- Use freezer-safe container
- Leave expansion space
- Label with date
- Canning:
- Use sterilized jars
- Process 15 minutes
- Follow proper canning procedures
- Store in cool, dark place
Safety Tips
- Never leave cooking sauce unattended
- Use long-handled spoon to avoid splatter
- Keep pot handles turned inward
- Use pot holders – sauce bubbles can splash
- Let cool before tasting or transferring
- Always check for signs of spoilage before use
- Keep away from heat and direct sunlight when storing
- Wash hands before handling ingredients
- Clean all surfaces after cooking
- Keep children and pets away from hot stove
