1-First Step: Prepare the grill and ingredients

Preheat your Traeger grill or pellet smoker to 275°F (135°C) using pecan pellets or similar wood for a smoky, nutty flavor. Gather all meatloaf components including ground beef, Italian sausage, eggs, breadcrumbs, seasonings, pepperoni, mozzarella, tomatoes, and basil.

2-Second Step: Mix the meatloaf base

In a large bowl, gently combine ground beef, Italian sausage, eggs, breadcrumbs, Italian seasoning, salt, and any optional BBQ or pecan rubs. Mix just until combined to maintain juiciness without overworking.

3-Third Step: Assemble the stuffed meatloaf

Divide the meat mixture in half. Form half into a 6-inch round or disc on parchment paper. Layer evenly with pepperoni slices, mozzarella, three tomatoes (mashed or sliced), and basil leaves. Cover the filling with the remaining meat mixture, sealing edges carefully.

4-Fourth Step: Position on grill and cook

Transfer the sealed meatloaf onto a greased cooling rack or grill pan to prevent sticking. Place it on the preheated Traeger. Smoke at 275°F for 1 hour to allow flavors to meld and cook thoroughly.

5-Fifth Step: Prepare and apply sauce

While the meatloaf cooks, heat olive oil in a pan over medium-low heat. Sauté minced garlic briefly, then add remaining San Marzano tomatoes, salt, oregano, and sugar if desired. Simmer gently, mashing tomatoes occasionally to create a rustic sauce.

6-Sixth Step: Finish cooking with sauce

After the initial hour, raise grill temperature to 300°F (150°C). Brush sauce generously over meatloaf surface. Continue cooking until internal temperature reaches 160°F (71°C), basting periodically for moisture.

7-Final Step: Rest and serve

Remove meatloaf from grill and allow to rest uncovered for 10-15 minutes to redistribute juices. Slice and serve warm, optionally garnished with fresh basil. Adjust seasoning or sauces as preferred for dietary needs.