These chocolate hazelnut Bourbon ice cream sandwiches are the third recipe in the ice cream sandwich series — and arguably the most indulgent yet. A creamy, deeply chocolatey Nutella ice cream base is sandwiched between Bourbon biscuits (cookies), frozen until solid, cut into 18 individual sandwiches and then half-dipped in melted milk chocolate that sets into a shell and cracks satisfyingly as you bite into it. The ice cream starts with the 2 ingredient ice cream base of vanilla custard and double cream (heavy cream), with Nutella stirred through in place of condensed milk — doing double duty as both the flavour and the sugar that keeps the ice cream smooth and scoopable rather than icy. No oven, no churner, five ingredients. Completely, absurdly delicious.

Why I Created This Recipe

The ice cream sandwich series has been one of my favourite things to develop this summer — and with the custard cream ice cream sandwiches and the Jammie Dodger raspberry ripple ice cream sandwiches already done, the Bourbon felt like the obvious and inevitable third instalment. A Bourbon biscuit paired with a chocolate hazelnut ice cream felt less like a creative decision and more like common sense.

The Nutella is the thing that makes this recipe slightly different from the others in the series. Where the custard cream and Jammie Dodger versions use condensed milk to keep the ice cream smooth and prevent it from freezing icy, this one uses Nutella — or any good quality chocolate hazelnut spread — in its place. The sugar content of Nutella is high enough to do exactly the same job as condensed milk, lowering the freezing point of the ice cream mixture and giving a smooth, creamy, scoopable result without any iciness. It also, of course, makes the whole thing taste extraordinarily good.

And then I felt a little extra and decided to dip half of each sandwich into melted milk chocolate. The chocolate sets into a thin, glossy shell that cracks the moment you bite into it, and the combination of crunchy chocolate shell, creamy hazelnut ice cream and chocolatey Bourbon biscuit is one of the best things I have made all summer.

The Ice Cream Sandwich Series

This is the third recipe in an ongoing series of no-churn, no-bake ice cream sandwiches, each one built on the 2 ingredient ice cream base and paired with a classic British biscuit (cookie). The custard cream ice cream sandwiches use a plain vanilla base with condensed milk; the Jammie Dodger raspberry ripple ice cream sandwiches add raspberry jam for a fruity ripple; and this Bourbon version uses Nutella in place of condensed milk for a deeply chocolatey, nutty result. Each recipe is different in flavour and character while following exactly the same format — making the series a brilliant template for experimenting with your own favourite biscuit and flavour combinations.

If you want to take the ice cream base even further, the homemade vanilla custard from the Small Batch Bakes series gives a richer, more deeply flavoured result than storebought custard — use the same quantity and follow exactly the same method.

Why Nutella Instead of Condensed Milk?

In the custard cream ice cream sandwiches and the Jammie Dodger raspberry ripple ice cream sandwiches, condensed milk plays a specific and important role — its high sugar content lowers the freezing point of the ice cream mixture, preventing large ice crystals from forming and keeping the finished ice cream smooth, creamy and scoopable rather than hard and icy.

In this recipe, the condensed milk is left out entirely — and Nutella, or any good quality chocolate hazelnut spread, takes its place. The reason this works is simple: Nutella has an exceptionally high sugar content — sugar is its first ingredient — which means it performs exactly the same function as condensed milk in terms of keeping the ice cream smooth and preventing iciness. At the same time, it adds the chocolate hazelnut flavour that makes this recipe what it is.

It is a two-for-one ingredient — flavouring and stabiliser in one — which is why no condensed milk is needed here. The Nutella is doing all the work.

The Chocolate Dipping Shell

Dipping half of each sandwich into melted milk chocolate is the step that takes these from very good to completely exceptional — and it is considerably simpler than it sounds.

The chocolate is melted and poured into a deep, narrow jug or container — something tall and narrow enough that the sandwich can be dipped in up to halfway without the chocolate being so shallow that you cannot fully submerge that half. Each frozen sandwich is then held by the undipped half and lowered into the chocolate up to the midpoint, lifted out cleanly and placed on a lined tray to set.

The frozen sandwich chills the chocolate almost immediately on contact, which means the shell sets very quickly — usually within a minute or two at room temperature, and even faster if returned to the freezer. Once set, the chocolate forms a thin, glossy shell that cracks satisfyingly the moment you bite into it, giving a contrast of textures — crunchy chocolate shell, creamy hazelnut ice cream, chocolatey Bourbon biscuit (cookie) — that is genuinely hard to improve upon.

Use a good quality milk chocolate with a cocoa content of around 35–40% for the best flavour and the most satisfying snap. Very cheap chocolate can have a waxy texture once set and does not crack in the same way.

Why You'll Want to Make This Recipe

No Oven, No Churn, Five Ingredients

No baking, no churning, no cooking beyond melting the chocolate. Whisk, layer, freeze, dip, freeze again. Five ingredients and around 20 minutes of active time — the freezer does everything else.

The Cracking Chocolate Shell

The half-dip in milk chocolate is the detail that makes these sandwiches genuinely spectacular. The shell sets hard against the frozen ice cream and cracks the moment you bite into it — the contrast of textures is extraordinary and the whole thing looks beautiful.

Makes Eighteen

This recipe makes 18 generous sandwiches — enough to fill the freezer for weeks, share with a crowd or bring to a summer gathering. They keep well for up to a month wrapped individually, and the chocolate shell makes them look impressive with almost no extra effort.

Nutella as Both Flavour and Stabiliser

The chocolate hazelnut spread does double duty here — flavouring the ice cream and keeping it smooth and scoopable without the need for condensed milk. It is a clever, efficient ingredient that makes this recipe even simpler than the others in the series.

My Top Tips for the Perfect Chocolate Hazelnut Bourbon Ice Cream Sandwiches

• Use a good quality full-fat storebought vanilla custard — or the homemade vanilla custard for a richer result. Full-fat is essential; reduced-fat versions freeze harder and produce a less creamy finished ice cream.
• Whisk the custard, double cream and Nutella together until completely smooth before pouring into the tin. Nutella is thick and can take a little longer to fully incorporate than condensed milk — keep whisking until there are no streaks remaining and the mixture is a uniform chocolate colour.
• The Nutella will make the mixture considerably thicker than the other ice cream sandwich bases — this is normal. It will still pour into the tin, just more slowly. Use a spatula to help spread it evenly over the Bourbon layer if needed.
• Cut the Bourbons in half carefully — a sharp knife and a firm, clean downward motion along the seam gives the cleanest split. Bourbons are more straightforward to cut than Jammie Dodgers but still benefit from a decisive cut rather than a tentative one.
• Lay the first layer of Bourbons chocolate-cream-side up and the second layer chocolate-cream-side down. Both chocolate cream centres face inward towards the ice cream, which maximises the Bourbon flavour in every bite.
• Line the tin generously with baking paper (parchment paper), leaving enough overhang on all sides to lift the frozen slab out cleanly for cutting and dipping.
• Freeze for the full four hours minimum before cutting — overnight is better. A completely frozen slab cuts more cleanly along the Bourbon lines and holds together better during the chocolate dipping process.
• Cut along the Bourbons — 18 Bourbons, 18 slices. Use a sharp knife and a single, decisive downward motion for the cleanest cuts.
• Use a tall, narrow jug or container for the chocolate dipping. The chocolate needs to be deep enough to fully submerge each sandwich halfway in one dip — a wide, shallow container means the chocolate is too shallow and you end up with an uneven dip line.
• Work quickly when dipping. The frozen sandwiches will begin to soften at room temperature — dip, drain briefly, place on the lined tray and return to the freezer as quickly as possible. Work through all 18 in one go rather than stopping between sandwiches.
• Let any excess chocolate drip back into the jug before placing the sandwich on the tray. A clean dip line looks far more professional than a pool of chocolate around the base.
• Return to the freezer for at least 30 minutes after dipping before serving or wrapping. The chocolate shell needs to be fully set before the sandwiches are handled or wrapped.
• Leave out for 10 minutes before eating. The ice cream needs a brief rest at room temperature to soften slightly — and the chocolate shell is at its most satisfying crack when the ice cream inside is just beginning to yield.

Ingredients and Tools You'll Need

Essential Ingredients

• 500g vanilla custard – full-fat storebought from the chilled section, or the homemade vanilla custard for a richer result
• 250ml double cream (heavy cream) – full-fat; the 2:1 ratio of custard to cream from the 2 ingredient ice cream base
• 220g Nutella or chocolate hazelnut spread – acts as both the flavour and the stabiliser that keeps the ice cream smooth; see the note above on why no condensed milk is needed
• 18 Bourbon biscuits (cookies) – halved into 36 halves; 18 halves for the bottom layer and 18 for the top, one sandwich per Bourbon
• 200g good quality milk chocolate – for the dipping shell; aim for around 35–40% cocoa content for the best flavour and snap

Essential Tools

• 20cm square baking tin – the same tin as the custard cream version; the right size for 18 Bourbon-sized sandwiches
• Baking paper (parchment paper) – for lining the tin and the dipping tray
• Large mixing bowl – for whisking the ice cream base
• Balloon whisk – for combining the custard, cream and Nutella
• Sharp knife – for cutting the Bourbons and the frozen slab
• Tall, narrow jug or deep container – for melting and dipping the chocolate
• Second lined baking tray – for the sandwiches after dipping

Storage

Wrap individual sandwiches tightly in baking paper (parchment paper) and store in a sealed container or freezer bag in the freezer for up to one month. The chocolate shell will protect the ice cream from freezer burn on the dipped half, making these particularly good keepers. For the best flavour and texture, eat within two to three weeks.

Remove from the freezer 10 minutes before eating and leave at room temperature to soften slightly before unwrapping and biting in.

Dietary Variations

Gluten-Free

Bourbon biscuits (cookies) contain wheat and are not gluten-free as standard — look for a gluten-free chocolate sandwich biscuit as a substitute. Check the labels on your custard and chocolate hazelnut spread too. All other ingredients are naturally gluten-free.

Dairy-Free

This recipe contains dairy in the custard, cream and chocolate — a full dairy-free adaptation requires dairy-free versions of all three, plus a dairy-free chocolate hazelnut spread and dairy-free Bourbon biscuits. All are available from specialist brands but require some searching. Use a dairy-free milk chocolate with a similar cocoa content for the dipping shell.

Dark Chocolate Dip

For a less sweet, more intensely chocolatey shell, use dark chocolate with a 60–70% cocoa content instead of milk chocolate. The shell will be slightly thinner as dark chocolate is less viscous when melted, and the flavour will be more bitter and complex — a brilliant contrast to the sweet Nutella ice cream if you prefer less sweetness overall.

White Chocolate Dip

A white chocolate dipping shell gives a beautiful visual contrast against the dark Bourbon biscuit (cookie) and adds a creamy, vanilla sweetness that works surprisingly well alongside the chocolate hazelnut ice cream. Melt and use in exactly the same way as the milk chocolate.

Frequently Asked Questions

Why does this recipe not use condensed milk?

The Nutella — or chocolate hazelnut spread — replaces the condensed milk used in the other ice cream sandwich recipes. Its very high sugar content performs the same function as condensed milk, lowering the freezing point of the ice cream mixture and preventing large ice crystals from forming. The result is an equally smooth, creamy and scoopable ice cream without needing an additional ingredient — the Nutella is doing both jobs at once.

How do I get a clean dip line on the chocolate?

Use a tall, narrow container so the chocolate is deep enough to fully submerge each sandwich halfway in one smooth dip. Lower the sandwich straight down to the halfway point, pause briefly to let any excess drip back, then lift out cleanly in one motion. Dragging the sandwich or dipping unevenly will leave an untidy line. Working with fully frozen sandwiches — not partially thawed ones — also gives a much cleaner result.

Can I use dark or white chocolate instead of milk chocolate?

Yes — see the variations section above. Dark chocolate gives a more intense, less sweet shell with a more pronounced snap; white chocolate gives a creamier, sweeter shell with a beautiful visual contrast. Both work in exactly the same way — melt, dip, freeze.

Can I skip the chocolate dipping?

Absolutely — the sandwiches are excellent without it. The chocolate shell is the detail that takes them from very good to completely spectacular, but if you want something simpler or you are short on time, the plain sandwiches are perfectly delicious as they are. Skip steps six and the second freeze and go straight to wrapping and serving.

How do I cut the frozen slab into 18 sandwiches?

Cut along the Bourbon biscuits — 18 Bourbons go in, 18 sandwiches come out. Use a sharp knife and a single, decisive downward motion rather than a sawing action for the cleanest cuts. If the slab is very hard, let it sit at room temperature for five minutes before cutting to make the process easier.

Is this recipe part of a series?

Yes — this is the third recipe in an ongoing ice cream sandwich series, following the custard cream ice cream sandwiches and the Jammie Dodger raspberry ripple ice cream sandwiches. All three start from the same 2 ingredient ice cream base and follow the same no-bake, no-churn format, with each one using a different classic British biscuit (cookie) and a different flavour profile.

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