In a Dutch oven, cook beef and onion over medium heat until meat is no longer pink; drain. Stir in remaining chili ingredients. Bring to a boil; reduce heat. Simmer, uncovered, for 1 hour.
In a large bowl, combine the egg, crumbs, salt, cumin and pepper. Crumble beef over mixture; mix well. Shape into four patties.
Grill, covered, over medium heat for 4-5 minutes on each side or until a thermometer reads 160° and juices run clear. Serve on buns with chili. Top with onion and cheese. Refrigerate or freeze remaining chili.