Chili loaded baked potatoes are large russet potatoes scrubbed clean, pierced with a fork, rubbed with olive oil and seasonings, then wrapped loosely in foil and grilled over indirect heat at 375°F to 425°F for 60 to 75 minutes until they reach 205°F to 210°F internal temperature. You slice them lengthwise, fluff the insides with a fork, then load them with shredded cheddar cheese and hot beef chili. Return them to the grill for 5 minutes to melt the cheese. Top with sour cream, crispy bacon, green onions, and jalapeños before serving.

The grilling method creates superior flavor compared to oven-baked potatoes. The indirect heat cooks the potatoes evenly while adding subtle smoke. Removing the foil and placing potatoes over direct heat for 2 to 3 minutes per side at the end creates crispy, charred skins. This texture contrast between fluffy interior and crispy exterior makes grilled baked potatoes more interesting than standard oven versions. The grill also keeps your kitchen cool during summer cookouts.

These BBQ loaded potatoes work equally well in the oven at 425°F for 50 to 60 minutes when outdoor grilling isn’t possible. The process is identical except you skip the smoke flavor and direct-heat crisping.

Why Russet Potatoes Are Essential for Loaded Baked Potatoes

Russet potatoes create the best chili loaded baked potatoes because their high starch content produces fluffy, light interior texture. When baked to 205°F to 210°F internal temperature, russet potato starches gelatinize completely. The cells separate easily. This creates that characteristic fluffy texture when you fluff the insides with a fork. Waxy potatoes like Yukon Gold or red potatoes have lower starch content. They stay dense and creamy rather than fluffy.

The thick skin on russet potatoes also holds up better to grilling and loading. Russet skins are tough enough to support heavy toppings without tearing. When crisped over direct heat, they become substantial and crunchy. Thinner-skinned potatoes can tear when you slice them open. The structural integrity of russet skins makes them ideal for loaded potato applications.

Russet potatoes also have neutral flavor that doesn’t compete with toppings. The potato serves as base for chili, cheese, sour cream, and bacon. Russets let these bold flavors shine. Yukon Gold potatoes have buttery flavor that can clash with savory chili. Red potatoes taste slightly sweet. Russets provide blank canvas.

The size of russet potatoes matters for this recipe. Look for large russets weighing 10 to 12 ounces each. Smaller potatoes don’t hold enough chili and toppings. Larger potatoes take too long to cook through. The 10 to 12 ounce size hits the sweet spot for cooking time and portion size.

Russets are also widely available and affordable. You can find them at any grocery store year-round. This makes the recipe accessible. You don’t need to search for specialty potatoes. Standard russets from the produce section work perfectly.

How Grilling Develops Better Flavor Than Oven Baking

Grilling BBQ loaded potatoes over indirect heat develops superior flavor because the potatoes absorb subtle smoke during the 60 to 75 minute cook time. Even wrapped in foil, trace amounts of smoke penetrate. This creates background smoke flavor that complements the chili and toppings. Oven-baked potatoes have no smoke character. They taste one-dimensional in comparison.

The direct heat finish after removing foil creates charred, crispy skins that oven baking can’t replicate. Placing the cooked potatoes over hot coals for 2 to 3 minutes per side chars the skins. This adds toasted, slightly bitter notes that balance the rich toppings. The Maillard reaction on the potato skin creates complex flavors. Oven-baked skins, even when crisped under the broiler, lack this depth.

Temperature fluctuations on the grill also improve texture. As you turn the potatoes every 20 minutes, different surfaces get varying heat exposure. This creates slight variation in the skin texture. Some areas are more crispy. Others are slightly softer. This textural variety is more interesting than uniformly baked oven potatoes.

Grilling also keeps your kitchen cool. During summer BBQ season, running the oven at 425°F for an hour heats up your house. Grilling moves the heat production outdoors. You can cook the potatoes while grilling other items. The efficiency of cooking multiple components on one heat source saves time and energy.

The indirect heat setup on a grill mimics convection oven cooking but with added benefits. Hot air circulates around the foil-wrapped potatoes. They cook evenly from all sides. The grill’s ambient temperature (375°F to 425°F) is perfect for potato baking. Lower temperatures take too long. Higher temperatures risk burning the foil.

What Makes Thick Chili Better for Loaded Potatoes

Thick chili works better for chili cheese baked potatoes because it stays on top of the potato rather than running off. Watery chili pools at the bottom of the plate. It makes the potato skin soggy. The chili should be spoonable but not runny. It should cling to the fluffy potato interior when you scoop a bite.

The ideal consistency is like thick stew. When you lift a spoonful, it should move slowly and maintain its shape. If it drips quickly or spreads thin, it’s too watery. If it’s so thick you need to scrape it from the spoon, it’s too thick. Somewhere between these extremes is perfect.

You can thicken thin chili several ways. Simmer it uncovered for 15 to 20 minutes. The excess water evaporates. Stir frequently to prevent sticking. The chili reduces and concentrates. Another method is mashing some of the beans against the pot side. The released starches naturally thicken the liquid.

Adding tomato paste also thickens chili effectively. Stir in 2 to 3 tablespoons of tomato paste. Simmer for 5 minutes. The paste adds body without changing flavor significantly. It also deepens the color to rich, dark red.

Cornstarch slurry provides quick thickening. Mix 1 tablespoon cornstarch with 2 tablespoons cold water. Stir into simmering chili. It thickens within 2 minutes. This method works well when you’re short on time. The cornstarch doesn’t affect flavor.

The ratio of liquid to solids in chili matters. Chili for loaded potatoes should have more meat and beans than sauce. You want each bite to have substantial chunks. Too much liquid dilutes the chili flavor. It also creates messy eating experience.

Why 205°F to 210°F Internal Temperature Is Critical

Grilled baked potatoes must reach 205°F to 210°F internal temperature for optimal texture. At this temperature range, the potato starches fully gelatinize. The cells separate completely. This creates light, fluffy interior that pulls apart easily with a fork. Lower temperatures produce gummy, dense texture.

Between 185°F and 200°F, potatoes are technically safe to eat but not perfectly fluffy. The starches are partially gelatinized. Some cells remain intact. The texture is acceptable but not ideal. The potato feels slightly heavy rather than light and airy.

Above 210°F, potatoes start drying out. Extended cooking evaporates too much moisture. The flesh becomes dry and mealy rather than fluffy and moist. The 205°F to 210°F window delivers perfect balance of fluffiness and moisture.

Using an instant-read thermometer takes the guesswork out of doneness. Insert the thermometer into the thickest part of the potato through the foil. Avoid touching the thermometer to the grill grate. Read the temperature quickly to minimize heat loss.

The knife test provides alternative doneness check. Insert a thin knife or skewer into the center. It should slide in with almost no resistance. The potato should feel soft throughout. Significant resistance indicates the potato needs more time.

Potatoes continue cooking slightly after removal from heat. This carryover cooking adds 2 to 5 degrees. If you pull potatoes at 203°F, they’ll reach 205°F to 208°F during resting. This carryover prevents overcooking while ensuring proper doneness.

Step-by-Step Instructions

Step 1: Prepare the Potatoes

Scrub 4 large russet potatoes under running water to remove dirt. Use a vegetable brush to clean thoroughly. Pat the potatoes completely dry with paper towels or a clean kitchen towel. Moisture on the surface prevents the oil and seasonings from adhering properly.

Pierce each potato 5 to 6 times with a fork. Poke all the way around the potato, not just one side. These holes allow steam to escape during cooking. Without holes, potatoes can explode from built-up steam pressure.

Rub each potato with about 1½ teaspoons olive oil. Coat the entire surface. The oil helps seasonings stick and promotes crispy skin development. It also prevents the foil from sticking to the potato surface.

Season all sides of each potato generously with kosher salt, black pepper, and garlic powder if using. The total seasoning is 1½ teaspoons salt and 1 teaspoon pepper divided among 4 potatoes. Press the seasonings into the oil so they adhere.

Step 2: Grill the Potatoes (Grill Method)

Set up your grill for indirect heat. For charcoal grills, push coals to one side. For gas grills, light burners on one side only. Target temperature is 375°F to 425°F in the indirect zone.

Wrap each seasoned potato loosely in aluminum foil. Don’t wrap too tightly. Leave some air space around the potato. This allows heat circulation while trapping steam.

Place the foil-wrapped potatoes on the indirect heat side of the grill. Close the lid. The ambient heat cooks the potatoes without direct flame contact.

Cook for 60 to 75 minutes, turning every 20 minutes. Rotate the potatoes to ensure even cooking. Check the grill temperature each time you turn them. Adjust vents or burner settings to maintain 375°F to 425°F.

Check for doneness at the 60-minute mark. Carefully open one foil packet slightly. Insert an instant-read thermometer into the center of the potato. It should read 205°F to 210°F. If not there yet, re-wrap and continue cooking.

Step 3: Crisp the Skins (Optional but Recommended)

When the potatoes reach target temperature, carefully remove the foil. The potatoes and steam are extremely hot. Use tongs and oven mitts. Discard the foil.

Place the unwrapped potatoes directly over the hot coals or direct flame. Grill for 2 to 3 minutes per side. You want char marks and crispy, slightly blistered skin. Watch carefully to prevent burning.

The direct heat crisps the exterior while the interior stays fluffy. This texture contrast is what makes grilled baked potatoes superior to oven versions. After crisping all sides, remove from direct heat.

Step 4: Bake the Potatoes (Oven Method)

Preheat your oven to 425°F. Place an oven rack in the center position. Put a baking sheet on a lower rack to catch any drips.

Prepare the potatoes exactly as described in Step 1. For crispy skins, place unwrapped potatoes directly on the oven rack. For softer skins, wrap in foil first.

Bake for 50 to 60 minutes until the internal temperature reaches 205°F to 210°F. Unwrapped potatoes may need closer to 60 minutes. Foil-wrapped potatoes cook slightly faster, around 50 to 55 minutes.

Check doneness by inserting an instant-read thermometer through the top of the potato. If you want extra crispy skins on oven-baked potatoes, remove them at 205°F and broil for 2 to 3 minutes. Watch constantly under the broiler.

Step 5: Prepare the Chili

While the potatoes cook, heat 2 cups of beef or turkey chili in a saucepan over medium-low heat. If using homemade chili, you likely already have the right consistency. If using canned or store-bought chili, it may need thickening.

Simmer the chili uncovered for 10 to 15 minutes, stirring occasionally. The chili should reduce and thicken. It should coat a spoon when you lift it. If it’s too thick, add beef broth 2 tablespoons at a time until you reach desired consistency.

Keep the chili warm over low heat while finishing the potatoes. You want steaming hot chili for assembly. Cold chili won’t melt cheese properly and creates disappointing eating experience.

Step 6: Load the Potatoes (First Stage)

Using a sharp knife, slice each potato lengthwise down the center. Don’t cut all the way through. Leave the bottom intact. The potato should open like a book.

Using a fork, fluff the inside of each potato. Scrape and pull the flesh to create fluffy, separated interior. This opens up space for toppings to nestle in.

Optional but delicious: add a pat of butter to each fluffed potato. The butter melts into the hot potato flesh and adds richness.

Immediately sprinkle shredded cheddar or Colby Jack cheese over the hot potato interior. Use about ⅓ cup cheese per potato. The residual heat starts melting the cheese.

Spoon ½ cup hot chili over the cheese on each potato. The chili should be steaming. Spread it evenly so it covers most of the potato surface. Some cheese should still be visible around the edges.

Step 7: Melt and Finish

Return the loaded potatoes to the grill (on the indirect heat side) or to the oven. Cook for 5 to 7 minutes until the cheese is fully melted and bubbly. The chili should be hot throughout.

For grill method, close the lid. For oven method, you can leave them uncovered. The brief heating melds all the hot components together.

Remove the potatoes from heat. Top each potato with 2 tablespoons sour cream, 1 tablespoon bacon bits, 1 tablespoon chopped green onions, and jalapeños if using.

Serve immediately while hot. Provide hot sauce on the side for those who want extra heat. These chili loaded baked potatoes are best eaten fresh when the cheese is melted and the potato is steaming.