Pound the chicken breasts to an even thickness. Combine the 1/2 cup buttermilk, 1 teaspoon hot sauce(optional), and 1 large egg in a bowl. Add the 2 chicken breast, ensuring they are fully submerged. Cover and refrigerate for at least 2 hours or overnight.
Mix the 1/2 cup all-purpose flour 1/2 teaspoon baking powder, 1/2 teaspoon garlic powder, 1/2 teaspoon onion powder, 1/2 teaspoon cayenne pepper 1/4 teaspoon kosher salt and 1/4 teaspoon black pepper in a shallow dish. This will be the breading for the chicken.
Remove the chicken breasts from the buttermilk marinade, allowing any excess to drip off. Dredge the chicken in the flour mixture, pressing gently to adhere the breading to the chicken.
Preheat the air fryer temperature to 390 degrees F, using the preheating butter, or preheat for 5-6 minutes. Carefully place the breaded chicken breasts into the preheated air fryer.
Set cook time for 6-8 minutes per side or until the chicken is golden brown and cooked through. Ensure the internal temperature reaches 165°F (74°C).
Spread 2 teaspoons mayo on both sides of the 2 brioche buns. Place a fried chicken breast on the bottom bun. Top with 6 slices pickle and cover with the top bun.
Your homemade Popeyes Chicken Sandwich is now ready to be enjoyed. Serve it while the chicken is still warm and crispy.