Keeping boudin from rupturing all over the grill

Do it on aluminum foil

Lower heat

Lower heat or indirect heat.

I double some heavy duty foil and spray it with Pam. Lowest heat seeking beneath it, with other burners on med-low to provide indirect heat. Flip and spin every 5 mins or so. I like it pretty browned, so it often splits near the end but doesn’t explode, and the foil contains it.

You gotta babysit it

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Why grill it is the question.

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This

There are a lot of variables to this problem. Temp, direct or indirect heat, time, internal temp when you start, how stuffed the casing is, and casing material all play into it.

Keep the direct heat off of it. Basically you should bake it on the grill. Always start with thawed boudin. Never throw frozen boudin on the grill. Remember that it is already cooked so you are just cooking it to your temp and color preference and trying to put a little smoke on it. Also, how stuffed the casing is matters. If it is loosely stuffed, it is hard to crisp the casing and it almost never splits. If it is overstuffed, it will split well before the insides are hot.

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what's the secret?

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No secret. You can reheat in different ways. If you are grilling at high heat and the boudin comes in contact with a metal grate then it will rupture.

I have hangers in my smoker so I usually hang the links and depending if I want smoke or not I may add wood chunks to the charcoal.

Wrap in foil...

Was about to say air fryer.