Beef Cheddar Melt Arby's

Nothing hits a nostalgic craving quite like a homemade Beef Cheddar Melt inspired by that comforting Arby's classic. Every bite is packed with juicy roast beef, melty sharp cheddar, and that tangy signature sauce—all stacked inside a fluffy onion bun. When you need something warm and soul-satisfying, this sandwich will absolutely deliver.

I whipped these up one chilly Sunday after a long week and the kitchen instantly felt cozier. Even my husband was stunned I managed to match the real deal.

Ingredients

• Ketchup: brings that classic sweet tomato base to the sauce go for a variety with no added corn syrup if you can
• Light brown sugar: highlights the tang and rounds out the acidity look for soft moist sugar
• Apple cider vinegar: offers zing and authentic Arby’s sauce brightness
• Worcestershire sauce: delivers a savory layer check the label for a deep color and rich aroma
• Garlic powder plus onion powder: boost savory flavor and make the sauce taste deeply seasoned
• Unsalted butter: creates the base for a creamy cheese sauce choose high quality butter for best melt
• All-purpose flour: thickens the sauce and gives a silky texture sift before measuring if you usually get clumps
• Whole milk: supplies richness and makes the cheese sauce smooth use cold milk for even thickening
• Sharp cheddar cheese: brings bold flavor try freshly grated for top meltability
• Low sodium beef broth: for warming the meat and keeping everything seasoned but not salty
• Thinly sliced deli roast beef: the key ingredient ask for paper thin slices for maximum tenderness
• Onion hamburger buns: give a soft sweet and aromatic base look for ones topped with real dried onion bits

Step-by-Step Instructions

Prepare the Arby’s Sauce:

Whisk ketchup light brown sugar apple cider vinegar Worcestershire sauce garlic powder and onion powder in a small mixing bowl for a full two minutes until the mixture is perfectly smooth and a little glossy Let it rest at room temperature while you continue with the recipe This step is essential for melding the flavors together and getting that proper tang

Make the Cheddar Cheese Sauce:

Melt unsalted butter in a small heavy saucepan over medium heat Add flour and stir constantly for about one minute until the paste turns slightly golden and loses its raw flour smell Gradually pour in the cold whole milk whisking steadily to prevent lumps Bring the mixture to a gentle simmer continue stirring for five minutes until it thickens to a sauce that will coat the back of a spoon Reduce heat to low then add sharp cheddar cheese stirring carefully until everything is velvety and smooth Remove from heat and keep covered

Warm the Roast Beef:

Pour beef broth into a large skillet and bring to a light simmer over medium heat Separate the roast beef slices so they do not stick together Add several slices at a time into the broth giving each batch a gentle turn with tongs after about one minute to warm through The beef should be soft and juicy but not left in the broth so long that it toughens Lift out each batch with tongs allowing the broth to drip away

Assemble the Sandwiches:

Arrange the bottom halves of the onion hamburger buns on a board or tray Spread a generous spoonful of Arby’s sauce onto each bun Layer warmed roast beef on next making sure each sandwich has plenty of beef Drizzle a big spoonful of hot cheddar cheese sauce across the beef then top with the remaining bun halves Serve right away so the cheese stays melty and the buns stay soft

Pin it

The bright bite of sharp cheddar has always been my favorite part since I was a teenager snagging these sandwiches with friends at the mall I cannot help but smile every time that sauce hits just right between the soft onion bun and the salty beef

Storage Tips

Store cooled leftover sandwiches in an airtight container in the fridge for up to two days

Keep the cheese sauce on its own in a mason jar or tightly lidded bowl and reheat gently before reassembling the sandwiches

For best texture keep the buns separate until just before serving to avoid sogginess

Ingredient Substitutions

Swiss or pepper jack cheese works well if you prefer a different flavor

Switch out the roast beef for thinly sliced turkey or chicken for a lighter sandwich

Try a classic sesame bun or pretzel roll if you cannot find onion buns

Serving Suggestions

Pair this hearty sandwich with simple oven fries or a crisp coleslaw

A side of sliced pickles or pickled jalapeños on the plate adds a great tangy contrast

If you want a true fast food night serve with curly fries and a dash more extra Arby’s sauce for dipping

Cultural and Historical Context

Arby’s Beef Cheddar Melt has been a fast food favorite in America since the eighties Roast beef sandwiches became widely popular as quick meal options for families on the go The signature combination of their special sauce and cheddar cheese created an American comfort classic that people can now master at home

Frequently Asked Questions

→ What cut of beef works best?

Thinly sliced deli roast beef is ideal for a tender, juicy filling that closely resembles the classic sandwich texture.

→ How do you make the cheese sauce creamy?

Slowly melt sharp cheddar into a roux and milk base, whisking constantly for a silky, clump-free finish.

→ Can different buns be used?

Onion hamburger buns are traditional, but plain or brioche buns also work well for holding the flavorful filling.

→ How do you keep the beef juicy?

Simmer the roast beef gently in beef broth just until warmed—overcooking can make it tough or dry.

→ What’s the role of Arby’s sauce?

The tangy, slightly sweet and savory sauce brightens each bite and balances the richness of the beef and cheese.

→ Any lighter options for the cheese sauce?

Try using low-fat milk or a reduced-fat cheddar to create a lighter version without sacrificing flavor.