Beef Cheddar Melt Arby's

This Beef Cheddar Melt brings that irresistible Arby's flavor home, piled high with tender roast beef and creamy cheddar cheese sauce on a pillowy onion bun. Every bite is comfort food at its best—the warmth of melted cheese, the tang of homemade sauce, and the cozy nostalgia of your favorite drive-thru sandwich. It is fast enough for busy nights and special enough for a game day meal. Serve it hot and toasty for the ultimate melty, gooey experience.

I first tried making this after a rough week when everyone needed a taste of something familiar. The kitchen filled with that amazing cheese aroma and my husband could not believe it was homemade. Now it is a go-to comfort meal in our house.

Ingredients

• Ketchup: gives that sweet tomato base to the sauce and using one without extra sweeteners lets the true flavor come through
• Light brown sugar: balances tang and adds a soft caramel note so look for fresh and slightly moist sugar
• Apple cider vinegar: sharpens the homemade sauce with real brightness and the best quality has a fruity fragrance
• Worcestershire sauce: provides deep savory flavor choose a bottle with a strong aroma and rich color
• Garlic powder and onion powder: round out the sauce and create layered savoriness
• Unsalted butter: is the start of a silky cheese sauce pick a butter that melts cleanly
• All-purpose flour: thickens the cheese sauce sift before measuring to avoid lumps
• Whole milk: forms the creamy base for melting cheese and keeps the sauce smooth use cold milk for consistent results
• Sharp cheddar cheese: is the star for flavor and meltability freshly grated cheddar will always melt best
• Low sodium beef broth: is great for warming the meat without making it too salty
• Thinly sliced deli roast beef: is key to the classic texture ask for slices as thin as possible
• Onion hamburger buns: have that soft slightly sweet lift and real dried onions add an irresistible aroma

Step-by-Step Instructions

Prepare the Arbys Sauce:

Whisk ketchup light brown sugar apple cider vinegar Worcestershire sauce garlic powder and onion powder for a full two minutes in a small bowl until smooth and glossy Let this rest at room temperature to blend the flavors while you prep everything else The wait makes all the difference

Make the Cheddar Cheese Sauce:

Melt unsalted butter in a heavy saucepan over medium heat Stir in flour and cook constantly for about a minute until golden and the flour smell fades Slowly pour in cold whole milk whisking continually to keep the sauce lump free Simmer for five minutes until thick enough to coat a spoon Lower the heat and stir in sharp cheddar cheese until the sauce turns velvety and smooth Cover to keep warm

Warm the Roast Beef:

Pour beef broth into a large skillet and bring to a gentle simmer Separate roast beef slices so they do not stick Add several at a time into the broth and turn with tongs after a minute The goal is to heat the beef through until juicy but not let it toughen Remove the slices with tongs letting the broth drain off

Assemble the Sandwiches:

Lay the bottom halves of onion buns on a board Spread each with plenty of Arby’s sauce Layer with warm roast beef Give each one a generous spoonful of cheese sauce right over the meat Top with the bun lids Serve straight away while the cheese is melty and the buns are fresh

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Sharp cheddar cheese has always been the highlight for me I still remember splitting sandwiches with friends after a movie in high school and the tang of the sauce packed between soft buns and salty beef still brings back those great memories

Storage Tips

Store leftover sandwiches in an airtight container in the fridge for two days max. For the best texture, keep the cheese sauce in a jar or bowl and reheat gently before adding to the sandwich. Wait to assemble until just before eating so the buns stay soft and not soggy.

Ingredient Substitutions

Swiss or pepper jack cheese melt smoothly if you like a different twist. If roast beef is not available, thin turkey or chicken delivers a lighter taste. Classic sesame or pretzel rolls can step in if you do not have onion buns on hand.

Serving Suggestions

This sandwich pairs best with a helping of oven fries or a crunchy coleslaw. You can stack pickles or pickled jalapenos on the side for an extra hit of tang. For the full fast food feel, go for seasoned curly fries and maybe an extra dip of that homemade sauce.

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Cultural and Historical Context

The Arby’s Beef Cheddar Melt became a hit in America back in the eighties and has since become a symbol of fast food comfort Classic roast beef sandwiches won hearts everywhere as a quick family meal and the unique sauce plus cheddar combo made it an iconic craving Today you can recreate the same flavors fresh at home

Commonly Asked Questions

→ What cut of beef is best for this sandwich?

Thinly sliced deli roast beef works best, offering a tender and juicy bite that echoes the classic Arby's texture.

→ How do you achieve a creamy cheese sauce?

Start with a butter and flour roux, add cold whole milk, and melt sharp cheddar cheese in gently, whisking for a smooth sauce.

→ Can I use other types of buns?

While onion buns give authentic flavor, soft brioche or sesame buns can be used as tasty swaps for the sandwich base.

→ How is the roast beef kept juicy?

Briefly warm the sliced beef in hot beef broth—just until heated through—so it stays moist and tender.

→ What makes the sauce unique?

A balanced mix of ketchup, brown sugar, vinegar, Worcestershire, and spices delivers the signature tang and sweetness.

→ Are there lighter cheese sauce options?

Swap in low-fat milk or a reduced-fat cheddar if you'd like a lighter but still flavorful cheese sauce for your melt.