Today I’m making the ultimate comfort food, the BBQ Beef Melt. It’s my take on the classic all-American beef and cheese melt, inspired by tasty roast beef sandwiches au jus.

My twist features smoked and shredded BBQ beef and melty cheese tucked between the best bread, Texas Toast. Get ready to savor the flavor of this epic grilled barbecue sandwich!

The BBQ Beef Melt is covered in bbq sauce and ready to eat.

Why You’ll Love the BBQ Beef Melt 

This is one of those mouthwatering recipes that I love to make and eat on a crisp-weather day in Tennessee. The combo of smoked beef, melted cheese, my favorite BBQ sauce, and crispy bread is unbeatable.

These delicious sandwiches aren’t exactly healthy eating, however, they are way more wholesome and satisfying than fast food. Every smoky, savory, delicious bite is downright comforting. And, then, that crutch that keeps the meat tender is so freakin’ delicious.

If you love shredded beef as much as I do, check out these other recipes: Shredded Beef Flautas, Smoked Beef Shank, Pulled Beef Chuck Roast and Pulled Beef Sliders with Steakhouse Baked Beans.

The final result, sliced in half, sandwich heaven.

BBQ Beef Melt Ingredients

  • Chuck Roasts – The chuck roast is an affordable cut of beef with incredible taste. For this recipe, it gets seasoned with my Big Bad BBQ Ale Rub, and with yellow mustard as the binder. Chuck roast is generally not considered lean meat, because it contains a moderate amount of fat. If you’re looking for less fat, try a sirloin roast. 
  • Crutch – The crutch helps keep the meat juicy while smoking and also makes a killer au jus. It’s a savory beef broth with white onions that gets tastier with the best part, beef tallow. 
  • Sliders – The sliders come together with the help of Texas Toast Slices. You’ll layer on some slices of cheese (sharp cheddar, white cheddar cheese, or pepper jack cheese work great!). Melted butter helps make the outside of the bread golden and crispy. Your favorite BBQ Sauce adds the final winning touch.

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Get ready, because this is fixin’ to become one of your favorite recipes. The BBQ Beef Melt isn’t just a sandwich, it’s a flavor-packed taste of home cooking that will keep you satisfied for a long time after the last bite.

These tasty beef and cheese sandwiches are perfect for game day, game night, Friday night with Netflix, or the next time you’re in the mood for a taste of foodie heaven. 

Homemade BBQ Sauce Recipe

If you don’t have BBQ sauce on hand, no worries! It’s actually pretty easy to make your own right at home!

In a large bowl or directly in a saucepan, add 1 cup of ketchup, 1/2 cup apple cider vinegar, 1/4 cup Worcestershire sauce, 1/2 cup brown sugar, 1/4 cup honey, and 1-2 tablespoons hot sauce (to your preferred heat).

Bring the sauce to a gentle boil, then reduce the heat to low and simmer for 15-20 minutes, stirring occasionally. For a thicker sauce simmer longer. To thin it out, add more ACV.

After cooling, store the sauce in an airtight Mason jar and keep it in the fridge for up to a few weeks. 


Alright, let’s dive into the Over the Fire Cooking recipe box and start making these mouthwateringly delicious BBQ Beef melts!

The Prep

First up, lay your chuck roasts on a baking sheet and cover them with the yellow mustard and Big Bad BB Ale Rub. Pop them in the fridge, uncovered, for at least 4 hours. If you’re feeling extra patient, go for an overnight flavor party. 

The beef is seasoned before getting into the smoker for the BBQ Beef Melt sandwiches.

Smokin’ Time

Now, fire up your smoker to a low and slow 250° degrees F. If you’re craving extra smoky flavor, toss in some wood chips or chunks. Bring the marinated chuck roasts out and onto the smoker, and let them smoke for about 3 hours. When they hit a toasty internal temperature of 165° degrees, they are ready for the next step.

The beef before and after smoking for a few hours.

Once they’re at temperature, transfer them to a foil bin and add the crutch: beef broth, beef tallow, and sliced white onions. The liquid should come up about halfway to the chuck roast’s height.

Seal that bin up tight with foil and back on the smoker at 300° degrees F until the meat turns tender and shred-ready. This might take another 3-4 hours.

Beef tallow is added to the crutch that helps keep the beef tender for the BBQ Beef Melt.

When those chuck roasts are getting ready to fall apart, let them rest for 20 minutes. Next, start shredding with a fork or with your hands if you’re not fussy.

Then, go ahead and strain and simmer down that au jus by half for the epic dipping sauce.

The beef is ready and shredded.

Beef Melt Assembly

Now, onto the assembly. Grab some thick-cut Texas toast, layer on a slice of cheese, and drizzle on some BBQ sauce. Next, heap on a handful of that shredded beef and more BBQ sauce, before adding another slice of cheddar and a slice of bread.

Place the beef melts into a cast iron skillet or plancha over medium heat with the butter. Then, toast the outside of the bread until golden brown.

The BBQ Beef Melt sandwiches are browned on the cast iron griddle.

When your melts are looking irresistible, pull them off, slice them, and then get ready to enjoy. Pair them with the au jus dipping sauce or more barbecue sauce!

What to Serve with the BBQ Beef Melt

Consider pairing these beef and cheddar sliders with options beyond the classic French fries or sweet potato fries. Potato salad, fresh crunchy coleslaw, or pickled red onions make excellent choices. And, of course, don’t overlook the option of dill pickles!

More Patty Melt Classics

Leftovers & How to Reheat 

If you have any leftovers, separate the meat from the bread. Wrap the meat tightly in aluminum foil and then keep it in the fridge for 3-5 days.

When you’re ready to indulge again, heat oven to about 375 degrees F. Grab a fresh slice of bread for an open-faced sandwich, top with cheese, and bake the sandwiches until the cheese is nice and bubbly. Top with more homemade BBQ sauce and serve with pickles and a side of cole slaw. 

The sandwich is dipped in BBQ sauce.


Can I make the shredded beef in the slow cooker? 

Even though this is a blog about cooking over the fire, I won’t stop you from using another in-door method!

After following the recipe prep instructions, place the marinated beef in the slow cooker, add beef broth, beef tallow (optional), and sliced white onions. Set the slow cooker to low and let it cook for about 8 hours until the beef is tender and shreds easily. Once done, shred the beef using forks, mix it with your favorite BBQ sauce, and enjoy! 

Could I add some caramelized onions? 

Absolutely! Adding caramelized onions to your BBQ Beef Melts is a fantastic idea. Caramelized onions bring a sweet and savory element that perfectly complements the rich flavor of the shredded beef. 

How can I turn this into a mushroom Swiss steak sandwich? 

In a cast iron skillet or frying pan, sauté sliced mushrooms until golden brown, season with salt and black pepper, then melt Swiss cheese over them for a flavorful topping. Assemble your sandwich by spooning the BBQ shredded beef onto one side of the toasted bread, top it with the sautéed mushrooms and melted Swiss cheese, and optionally add barbecue sauce or Dijon mustard. 

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The BBQ Beef Melt is the ultimate comfort food.

BBQ Beef Melt

Get ready for the ultimate comfort food: BBQ Beef Melts. Smoked beef that falls apart after smoking is layered with melted cheese and your favorite bbq sauce between Texas Toast.
Author:Derek Wolf
5 from 3 votes
Prep Time: 1 hour
Cook Time: 8 hours
Total Time: 9 hours
Course: Dinner, Lunch
Cuisine: American
Servings: 6 people




  • 32 oz Beef Broth
  • 1/2 cup Beef Tallow
  • 2 cups Sliced White Onions


  • 8-10 Texas Toast Slices
  • 6-8 Cheddar Cheese Slices
  • 1 cup Melted Butter
  • 1 cup Favorite BBQ Sauce


  • In a bowl, mix together the salt, pepper and garlic.
  • Place your chuck roasts on a baking sheet, lather with yellow mustard and generously season all sides in order to completely cover the roasts.
  • Place them in the fridge, uncovered, for at least 4 hours but ideally overnight.
  • Preheat your smoker to about 250 degrees F. Add some wood chips or wood chunks if desired for extra smoky flavor.
  • Pull your chuck roasts out and place on the smoker to cook until 165 degrees F internal (about 3 hours).
  • Once the chuck roasts have hit temperature, pull them out and place in a large foil bin.
  • Fill into the bin your beef broth, beef tallow and sliced white onions. The liquid in the bin should come up to 50% of the chuck roast’s height, so add more or less if necessary.
  • Tightly cover your bin with foil and place back on the smoker at 300F to smoke until the meat is tender to probe and shreddable (another 3-4 hours).
  • Once the chuck roasts are done, pull them off and let them rest for 20 minutes.
  • After the rest, pull the chuck roasts out and shred them up. (Optional: strain and simmer the au jus down by half for a dipping sauce)
  • Build your melt with thick cut texas toast, slice of cheddar cheese, some bbq sauce, handful of shredded beef, more bbq sauce, another slice of cheddar beef and another thick cut sliced brioche.
  • Add the melts to the skillet and toast the bread till golden brown.
  • When the melts are done, pull off and slice. Add to a bowl of bbq sauce or strained broth from the crutch. Dip the patty melts in the sauce for serving. Enjoy!



Homemade BBQ Sauce Recipe
In a large bowl or directly in a saucepan, add 1 cup of ketchup, 1/2 cup apple cider vinegar, 1/4 cup Worcestershire sauce, 1/2 cup brown sugar, 1/4 cup honey, and 1-2 tablespoons hot sauce (to your preferred heat). 
Bring the sauce to a gentle boil, then reduce the heat to low and simmer for 15-20 minutes, stirring occasionally. For a thicker sauce simmer longer. To thin it out, add more ACV. 
After cooling, store the sauce in an airtight Mason jar and keep it in the fridge for up to a few weeks. 


Serving: 8Oz | Calories: 1334kcal | Carbohydrates: 66g | Protein: 67g | Fat: 93g | Saturated Fat: 52g | Polyunsaturated Fat: 7g | Monounsaturated Fat: 31g | Trans Fat: 3g | Cholesterol: 290mg | Sodium: 1733mg | Potassium: 1584mg | Fiber: 7g | Sugar: 21g | Vitamin A: 2140IU | Vitamin C: 9mg | Calcium: 532mg | Iron: 22mg

Derek Wolf

Derek is the driving force behind Over the Fire Cooking. He started cooking with live fire in 2016 and decided to start a social media page so his friends and family could follow the journey. Fast forward to today and Over the Fire Cooking has spread across multiple platforms with millions now following Derek's fire cooking journey. He's a southern fellow who enjoys everything from classic BBQ to Central and South American inspired dishes. Whatever he's cooking up, it's guaranteed to be so freakin' delicious!

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