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Prepare enough coals for a medium-hot fire or set one side of a gas grill to medium-high.
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Heat a skillet, preferably cast iron, on the grill. Add the olive oil and heat until just smoking. Learn about the benefits of cast iron cooking in this infographic.
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Add the sausage and cook, stirring to break up the meat, until browned. Add the onion and bell pepper and cook, stirring, until they soften, about 4 minutes. Add the garlic, green chiles, and chili powder, and cook for 1 minute more. Remove from the heat and set aside.
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Butter a 9×13-inch baking dish.
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In a large bowl, whisk together the eggs and half-and-half along with the grated cheese, scallions, cilantro, hot sauce, and salt.
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Spoon 1/2 of the sausage mixture into the bottom of the baking dish and top with 1/2 of the tortilla chips, breaking the chips into roughly 1-inch pieces. Repeat with the remaining sausage mixture and tortilla chips.
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Pour the egg mixture into the pan and wiggle the pan a bit so the egg settles.
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Wrap the entire baking dish in aluminum foil. Push the coals to one side of the coal grate. Place the baking dish on the opposite side of the grill rack from the coals. (If using a gas grill, place the baking dish on the side of the grill away from the heat.) Cover the grill and cook for about 40 minutes or until a knife inserted into the custard comes out clean.
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Remove from heat and let cool for a few minutes before unwrapping. Be careful of escaping steam when you open the foil. Serve immediately.
alable freezer bag, and keep cold in arefrigerator or ice-filled cooler when ready to use.
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