Clean a section of PVC pipe (1 ½” – 2 ½ “in diameter, at least a foot long). Stand the bologna on end and gently push the pipe down through the center of the bologna. Pull out the pipe and remove the core of meat that gets inside of it.
Cut 2 plugs from the core and plug one end of the bologna.
Mix the BBQ ½ cup of sauce with the cheese.
Add as much of the cheese as you can fit and plug the remaining end with the other piece of the core.
Rub outside of chub with mustard and then sprinkle with a rub.
Fire up your smoker to 250 F. Add your desired cooking wood, but use only a little and don’t use anything overpowering.
Smoke for 3 ½ hours turning once half way through.
Brush the outside with the BBQ sauce and smoke for another 30 minutes.
While the bologna is cooking grill the onions. Let cool and thinly slice.
Remove bologna from the smoker and let set at least 30 minutes. Don’t rush or the cheese will run out when you slice it.
Cut the bologna into thick slices.
Build the sandwiches with the bologna, mustard, onions and hot sauce.