This is a bit of a labor of love that I've been working on for a while now. While I normally avoid vegetarian facsimiles of meaty meals, this is an exception. Even as a vegetarian for decades, I still occasionally miss the smoky goodness of a pulled pork sandwich or the tangy richness of a brisket slow cooked all night then finished with homemade bbq sauce. Developing a good, realistic-tasting BBQ sandwich has been on my to-do list for a long time. So long, in fact, that I 'test kitchened' this recipe extensively the last few months, making literally dozens of different variations, until I landed on this, the ideal vegetarian bbq sandwich. It is smoky, tangy, rich, satisfying.
Note that I also use homemade BBQ sauce for this. Just about every store-bought sauce is too sugary and without adequate vinegary bite to make this recipe work. So I don't recommend you use any store-bought BBQ sauce.
You'll need some way to smoke some of your ingredients. You can obviously use a standalone outdoor smoker. I actually use an indoor smoker: the Nordic Ware kettle smoker. Don't own a smoker? NO PROBLEM! The internet is loaded with different ways to make your own homemade version. Most of these require little more than a Dutch oven with a heavy lid, some aluminum foil, a steamer basket or strainer, and smoker wood chips (available online or at any gourmet store or retailer that sells grilling supplies). It's easy to make either an outdoor version or a stovetop version for smoking inside.
Finally, you need to start this a day or so ahead of time, since you need to freeze and then thaw the tofu. Freezing it significantly changes the texture and ability to soak up the marinade, so this is a pretty essential step.
This makes about 6 'brisket' sandwiches.
Prep time: 3 cocktails
Tofu + Marinade
1 15-ounce brick of tofu
3 TBSP orange juice
1 TBSP miso paste
2-3 TBSP canola oil
2 TBSP Worcestershire sauce
2 TBSP soy sauce
3 TBSP red wine
Several dashes of MSG or dried mushroom powder (optional)
~1/2 cup smoked walnuts (optional, see note below)
The BBQ sauce
6 TBSP butter
2 tsp brown sugar
2 tsp agave or honey
Fixings
Buns
Grated high-end white cheddar
Chopped scallions
Pickled red onions (you can use any basic online recipe)
Additional optional toppings: coleslaw, chopped pickles, fresh or pickled jalepeno, thinly sliced fresh cucumber or radish, fried shallots, avocado pieces, and/or caramelized onions.
Note on walnuts: I like to add smoked walnuts to this for two reasons: the walnuts absorb a lot of flavor when smoked, so they turbocharge the flavor of the sandwiches. The walnuts also have a texture that mimics meat a little bit when chopped up and combined with tofu. It's not exact, but it is a nice addition. Walnuts should be dry smoked (so you cannot smoke them with the tofu). I've found that 20-30 minutes is usually plenty of time in my kettle smoker, but results will vary. After smoked, transfer smoked nuts to a food processor and pulse a few times until you have mostly little pieces halfway between the size of Nerds candy pieces or a bit smaller (don't overmix, or else you risk making smoked walnut butter). Add the walnuts to the tofu after the tofu is done cooking on the stovetop in the BBQ sauce. The amount you use isn't super important, but I usually start with about 3/4 cups of whole walnuts, which breaks down to about 1/2 cup of crumbles in the food processor.
First, you'll need to freeze the tofu completley and then let it thaw out. This gives it a meatier texture and allows it to soak up the marinade.
Next, press the tofu for an hour or so in a tofu press or wrapped in a towel and placed under a heavy pan or books. After pressed, pat tofu dry and tear it apart with your hands into "pulled pork" or "shredded chicken"-like pieces. It won't be exactly the same, but you'll discover that the tofu has a grain that you can kind of work with to get pretty close. Don't shred the pieces so small that they won't be able to sit in the smoker without falling through the grates or holes (small bite-sized pieces is good).
Now combine all the marinade ingredients EXCEPT the tofu and walnuts in a mixing bowl and whisk well. Combine tofu cubes and marinade in an airtight container and allow to marinade a minimum of 30 minutes and up to 24 hours, stirring gently occasionally, so as to not break up the tofu pieces.
Now smoke the tofu pieces. The method will vary depending on your smoker, so it may require some experimentation. For my Nordic Ware kettle smoker, I do a 60 minute "wet" smoke at 190F on the stovetop with hickory wood chips. The liquid I like to use for smoking is 2 cans of beer, which gives the tofu a bit of extra flavor, though water is fine too. Allow to cool to room temperature after smoking. Then transfer to a plate and chill completely in the refrigerator, uncovered.
Heat your oven to 300F.
OPTIONAL STEP: This is to give the tofu a more meaty texture, if you want. After tofu has chilled in the refrigerator, spread pieces so they're not touching on a well-greased cookie sheet and bake for 15-30 minutes, or until they have become a little more toothsome and "meaty." Remove from oven and allow to cool, but leave the oven on at 300F, as you'll be using it again shortly.
Now make the sauce by melting the butter in a medium saucepan over medium heat. Once melted, add the BBQ sauce, sugar, and agave/honey. Stir until everything gets hot and starts to simmer. Whisk it, or, ideally, use an immersion blender, until the sauce is fully integrated. Now add your cooled tofu pieces and stir very gently with a rubber spatula, so as to not break the tofu. Bring bbq sauce/tofu to a boil and remove from heat. Now stir in those walnut pieces, if using.
Now build your sandwiches: take a standard size cookie sheet and line with foil. Put your ~6 bun bottoms on the pan and top with the bbq tofu mixture. Now top each sandwich with a couple generous pinches of white cheddar and place the pan uncovered in the oven (you can also put the bun tops in the oven to toast as well, if you want).
Since tofu should already be warm, all you need to do is melt the cheese, so the sandwiches likely only need to be in the oven for a few minutes. Once the cheese is melted, remove from oven, add the scallions, pickled onions, and any of the optional ingredients you might also be using. Affix the top bun and enjoy!