The key to perfect grilled smash burgers is high heat and the right technique. The combination of grill heat and cast iron creates the ideal surface for achieving those coveted crispy edges.

1. Step 1: Prep The Grill And Ingredients

   Preheat your grill to high heat (450-500°F). If using a gas grill, preheat all burners. For charcoal, arrange coals for direct high-heat cooking. Place a cast iron griddle or plancha on the grill grates to preheat. Divide ground beef into 8 loose balls (2 oz each) - don't pack them tight. Season with salt and pepper just before cooking.

2. Step 2: Master The Smash Technique

   Place 2 beef balls on the hot griddle, leaving space between them. Immediately smash each ball with a heavy spatula or burger press, applying firm downward pressure for 10-15 seconds. The patties should be very thin (about 1/4 inch) with irregular, lacy edges. Don't move them for 2-3 minutes to develop a deep crust.

3. Step 3: Flip And Stack For Double Patties

   When edges are deeply browned and crispy (2-3 minutes), flip the patties using a thin spatula. Cook for another 1-2 minutes, then place cheese on one patty and stack the second patty on top. This creates a double smash burger with maximum flavor. Repeat with remaining beef balls.

4. Step 4: Toast Buns And Finish Assembly

   While burgers rest, butter the cut sides of buns and toast them on the grill for 30-60 seconds until golden. Grill the sliced onions for 2-3 minutes until slightly charred. Assemble burgers with sauce on bottom bun, lettuce, tomato, double patty stack, grilled onions, pickles, and top bun.

Let burgers rest for 2-3 minutes after cooking to allow juices to redistribute. The internal temperature should reach 160°F for food safety.