There’s just something about a hot, melty sandwich that hits differently—especially when it’s loaded with layers of savory meats, gooey cheese, and toasted to perfection. This Ultimate Baked Italian Sub Sandwich Recipe delivers everything you love about a classic sub, but with an extra boost of flavor thanks to buttery garlic seasoning and a warm, oven-baked finish. I first made this baked Italian sub on a busy weekend when I needed something quick but hearty to feed a hungry crowd. It was an instant hit. The combination of chicken ham, beef salami, and crispy turkey bacon tucked between gooey layers of provolone and mozzarella cheese? Pure comfort. And the best part? It comes together with simple ingredients and minimal prep. Whether you’re feeding your family on a weeknight, looking for a great game-day sandwich, or just want to take your lunch to the next level, this recipe checks all the boxes. You get that classic deli flavor but with a warm, toasted twist that makes each bite incredibly satisfying. Let’s dive into what you’ll need to get started and walk through the first steps of assembling this crave-worthy sandwich.

Ingredients You’ll Need:

• 4 hoagie rolls
• 4 tablespoons butter, melted
• 1 teaspoon garlic powder
• ½ teaspoon dried Italian seasoning
• 8 slices chicken ham
• 8 slices beef salami
• 8 slices turkey bacon, cooked
• 8 slices provolone cheese
• 1 cup shredded mozzarella cheese
• ½ cup sliced pepperoncini peppers (optional)
• ¼ cup mayonnaise
• ¼ cup sliced red onions
• ¼ cup shredded lettuce
• Tomato slices

Step-by-Step Instructions:

Step 1: Preheat the Oven

Preheat your oven to 375°F (190°C). You’ll want it fully heated before the sandwiches go in so they bake evenly and the cheese gets perfectly melty.

Step 2: Prep the Rolls

Slice each hoagie roll in half lengthwise, being careful not to cut all the way through—leave the back side attached so the sandwich holds together better. This also makes it easier to fill and serve.

 

Step 3: Make the Garlic Butter

In a small bowl, stir together the melted butter, garlic powder, and Italian seasoning. Brush this flavorful mixture generously on the inside of each roll. This step adds a rich, savory base and gives the rolls a perfectly toasted finish.

 

Building and Baking Your Ultimate Baked Italian Sub Sandwich

Now that your rolls are prepped and flavored with that buttery garlic seasoning, it’s time to layer up the meats and cheeses that give this sub its signature flavor. The beauty of this Ultimate Baked Italian Sub Sandwich is in the combination—each bite is savory, melty, and full of bold Italian-inspired taste. And because the sandwiches are wrapped and baked, all that flavor gets sealed in for a hot and satisfying meal that’s way better than anything you’d grab at a sandwich shop.

Step 4: Layer the Meats and Cheese

Open up each roll and layer with:

• 2 slices of chicken ham
• 2 slices of beef salami
• 2 slices of cooked turkey bacon
• 2 slices of provolone cheese

You want each roll to be stacked but not overfilled. The balance of meats and cheese is key here—enough to satisfy without overwhelming the sandwich.

 

Step 5: Add Mozzarella and Optional Toppings

Sprinkle a generous handful of shredded mozzarella cheese over the layered meats. If you like a bit of heat or tang, add a few sliced pepperoncini peppers at this point. They’re optional, but they really elevate the flavor and add a nice zing. Then, gently press the roll closed. It’s okay if it’s slightly overstuffed—the foil wrap will help keep everything in place while baking.

Step 6: Wrap the Sandwiches

Wrap each sandwich tightly in foil. This helps the cheese melt evenly and keeps the bread soft on the inside while allowing the outside to toast slightly. Make sure the foil is secure but not overly tight—you want room for the heat to circulate inside.

 

Step 7: Bake

Place all of the wrapped subs on a baking sheet and bake at 375°F (190°C) for 15–20 minutes, or until the sandwiches are heated through and the cheese is fully melted. If you want the outside of the rolls to be extra crispy, you can open the foil in the last 2–3 minutes of baking and let the tops brown slightly.

Step 8: Unwrap and Add Fresh Toppings

Once the sandwiches are baked, carefully unwrap them from the foil. Now comes the final touch: add mayonnaise, sliced red onions, shredded lettuce, and tomato slices to each sandwich, if desired. These fresh ingredients add a great crunch and coolness that balances the hot, cheesy filling perfectly.

 

Tips and Variations to Make It Your Own:

• Switch up the meat: Use traditional Italian cold cuts like capicola, prosciutto, or mortadella if you want a more classic deli-style version.
• Add a spicy kick: Layer in some crushed red pepper or spicy giardiniera for extra heat.
• Make it saucy: Spread a thin layer of marinara or pizza sauce inside the roll before baking for a pizza-sub hybrid.
• Go meatless: Skip the meat and add grilled veggies like zucchini, mushrooms, and roasted red peppers for a vegetarian option.
• Add pesto: A thin swipe of pesto under the cheese layer adds herby depth and richness.

 

Ultimate Baked Italian Sub Sandwich: FAQ and Final Thoughts

At this point, your Ultimate Baked Italian Sub Sandwich is out of the oven, the cheese is perfectly melted, and the fresh toppings are layered in for that final crunch. Whether you’re serving it for lunch, dinner, game day, or feeding a crowd, this sandwich hits all the right notes. But before you dig in, let’s answer a few common questions that may come up while preparing or customizing this recipe.

Can I make these sandwiches ahead of time?

Yes! You can assemble and wrap the sandwiches in foil, then refrigerate them for up to 24 hours before baking. When ready to eat, just pop them into the oven as directed—no need to adjust the baking time.

Can I use different bread besides hoagie rolls?

Definitely. Sub rolls, ciabatta, or even baguettes work great. Just make sure the bread is sturdy enough to hold up to the filling and baking process without getting too soggy.

What’s the best way to keep the sandwiches warm for a party?

Once baked, keep the wrapped sandwiches in a warm oven (around 200°F) until ready to serve. You can also place them in a slow cooker on the “keep warm” setting if you’re feeding a crowd buffet-style.

Do I have to use foil?

Foil helps trap the heat and moisture so everything melts evenly and the bread doesn’t dry out. If you skip the foil, you may end up with a drier sandwich. It also makes cleanup a breeze.

Can I reheat leftovers?

Yes! Wrap the sandwich in foil and bake at 350°F for about 10 minutes or until heated through. Microwaving is faster, but the bread may soften too much.

Can I add sauces inside before baking?

Absolutely. A swipe of marinara, mustard, or pesto inside the roll before layering the meat and cheese is a delicious way to customize the flavor.

Final Thoughts: Why You’ll Love This Ultimate Baked Italian Sub

This Ultimate Baked Italian Sub Sandwich is everything a hot sub should be—cheesy, savory, loaded with flavor, and just the right mix of crispy and melty. The garlic butter on the rolls adds an extra punch of flavor, while the melted cheeses pull everything together in a way that’s comforting and crave-worthy. It’s also incredibly easy to make, scalable for a crowd, and endlessly customizable to suit your taste or whatever ingredients you have on hand. Whether you go all out with toppings or keep it simple and classic, this baked sub is guaranteed to become a go-to in your recipe rotation. So next time you’re in the mood for something satisfying, skip the sandwich shop and make this at home. It’s faster than takeout—and a whole lot more delicious. Enjoy! Print