During a community yard sale last spring, I struck up a chat with a retired truck driver who’d stopped by for a glass of lemonade and stayed for the smell of dinner wafting from my open kitchen window.
His name was Roy, and he wore a weathered cap and a big grin that told me he’d lived a hundred stories. When he spotted the sandwich on my plate, gooey cheddar, stacked roast beef, soft onion bun, he chuckled and said, “You’re trying to one-up Arby’s, huh?”
That led to a full hour sitting under my carport, trading tales and sandwich opinions like old neighbors. He talked about quick meals on the road and how Arby’s Beef And Cheddar was a rare treat between long hauls. That sparked something in me, not just nostalgia, but the challenge of making that roadside favorite at home, with better ingredients and a whole lot more heart.
Later that evening, I tested a homemade Arby’s sauce with just the right balance of tang and sweetness. The cheddar sauce came next—simple, velvety, and comforting. When I finally built the sandwich and handed one to Roy (who had come back with a soda and a grin), he gave a quiet nod after the first bite. “You’ve got it,” he said. And just like that, I knew this recipe belonged in my notebook—and now, on the blog.
Short Description
A homemade take on Arby’s classic beef and cheddar sandwich—thinly sliced roast beef warmed in broth, smothered in creamy cheddar sauce and finished with tangy “Arby’s-style” onion sauce.
Key Ingredients
Arby’s sauce
- ½ cup ketchup
- 2 tbsp packed light brown sugar
- 1 tbsp apple cider vinegar
- 1 tbsp Worcestershire sauce
- ½ tsp garlic powder
- ½ tsp onion powder
Cheese sauce
- 1 tbsp unsalted butter
- 1 tbsp all-purpose flour
- 1 cup whole milk
- 6 oz shredded sharp cheddar cheese
Sandwich assembly
- 2 cups low-sodium beef broth
- 1 lb thinly sliced deli roast beef
- 4 onion hamburger buns
Tools Needed
- Mixing bowl
- Small saucepan
- Whisk
- Large skillet
- Tongs
- Spoon
- Measuring cups and spoons
Cooking Instructions
Step 1: Make the Arby’s Sauce
In a small bowl, whisk together ketchup, brown sugar, apple cider vinegar, Worcestershire sauce, garlic powder, and onion powder. Set aside.
Step 2: Prepare the Cheese Sauce
Melt butter in a saucepan over medium heat. Stir in flour and cook 1 minute. Slowly whisk in milk, bringing the mixture to a gentle simmer. Cook for 5 minutes, then stir in shredded cheddar until smooth.
Step 3: Warm the Roast Beef
In a large skillet, bring beef broth to a low simmer for about 5 minutes. Separate roast beef slices and gently warm 1–2 minutes in the broth—watch for doneness so meat doesn’t get overcooked.
Step 4: Assemble the Sandwiches
Spread Arby’s sauce evenly on the bottom half of each onion bun. Top with warmed roast beef and drizzle generous amounts of cheese sauce. Cover with the bun’s top half, pressing gently.
Troubleshooting Tip:
If cheese sauce becomes too thick, thin with a bit of warm milk one tablespoon at a time until it pours smoothly.
Why You’ll Love This Recipe
Flavor Explosion: Homemade sauce adds sweet, tangy notes that complement savory roast beef.
Quick and Easy: Simple ingredients and fast prep—ready in about 20 minutes.
Versatile: Easily scaled for more sandwiches; great for game nights or weeknight dinners.
Comfort Food: Warm, cheesy, and satisfying without deep-frying.
Nostalgic: Brings back memories of shared meals, but better because it’s homemade.
Mistakes to Avoid & Solutions
Sauce Separation: Overheating cheese sauce may cause separation.
Solution: Keep heat low when adding cheese; stir slowly until melted.
Tough Roast Beef: Overcooked meat loses moisture and texture.
Solution: Simmer just 1–2 minutes in broth—observe for gentle steam.
Soggy Bun Bottom: Sauce-heavy bottom buns may get soggy.
Solution: Toast buns lightly under broiler or in a skillet before assembly.
Serving and Pairing Suggestions
Serve warm and gooey right off the skillet.
Pair with crisp coleslaw or a light green salad.
Dipping sauces like extra Arby’s sauce, Dijon mustard, or pickles add flair.
Perfect for casual family tables or small gatherings—serve plated or buffet-style.
Storage and Reheating Tips
Store: Keep leftovers in airtight containers in the fridge up to 2 days.
Reheat (Skillet): Reheat sandwiches over low heat with a lid for 3–4 minutes until cheese melts.
Reheat (Microwave): Wrap in a damp paper towel and heat in 30-second bursts to preserve moisture.
Cheese Sauce: Store separately and reheat gently in a saucepan, adding milk if needed.
FAQs
1. Can I use other cheese for the sauce?
Yes—Swiss or smoked gouda adds unique flavor. Just adjust cheese amount to taste.
2. Is crusty bread okay instead of buns?
Definitely—ciabatta or kaiser rolls work beautifully.
3. Can I make this ahead?
Yes—cook sauce and warm beef in advance; assemble and heat just before serving.
4. Can I use leftover roast beef?
Yes, or even cooked brisket—it adds more depth of flavor.
5. How spicy is this?
Mild—if you prefer a kick, stir in a pinch of cayenne to the sauce or cheese.
Tips & Tricks
For extra richness, stir 1 teaspoon Dijon mustard into the cheese sauce.
Toast buns face down in the skillet after warming the meat—adds extra crunch.
Leftover sauce is great on fries, veggies, or mashed potatoes.
Save any extra Arby’s sauce in the fridge as a dipping condiment.
Recipe Variations
1. Philly-Style Beef & Cheddar
Use thin sliced roast beef
Add sautéed onions and green peppers
Replace Arby’s sauce with garlic aioli on buns
2. BBQ Beef and Cheddar
Replace ketchup mixture with BBQ sauce
Add crispy onion straws on top of cheese for crunch
3. French Dip Style
Dillute beef broth with a splash of red wine
Serve sandwich alongside warmed au jus for dipping
Final Thoughts
Roy stayed until dusk, and before he left, he asked if I had any foil so he could bring a sandwich home for his wife. That’s the kind of moment that sticks with you, not just the food, but the connection made over it.
This sandwich may be inspired by something familiar, but in my kitchen, it became something entirely our own. Roy still stops by now and then, usually when he smells cheddar in the air. And every time, it reminds me how a simple sandwich can open doors to stories you didn’t even know you were missing.
Arby's Beef And Cheddar Copycat
Print ThisIngredients
- Arby’s sauce
- ½ cup ketchup
- 2 tbsp packed light brown sugar
- 1 tbsp apple cider vinegar
- 1 tbsp Worcestershire sauce
- ½ tsp garlic powder
- ½ tsp onion powder
- Cheese sauce
- 1 tbsp unsalted butter
- 1 tbsp all-purpose flour
- 1 cup whole milk
- 6 oz shredded sharp cheddar cheese
- Sandwich assembly
- 2 cups low-sodium beef broth
- 1 lb thinly sliced deli roast beef
- 4 onion hamburger buns
Instructions
Step 1: Make the Arby’s Sauce
Whisk together ketchup, brown sugar, vinegar, Worcestershire, garlic powder, and onion powder in a small bowl. Set aside.
Step 2: Prepare the Cheese Sauce
Melt butter in a saucepan. Stir in flour, cook 1 minute, then whisk in milk. Simmer 5 minutes, add cheddar, and stir until smooth.
Step 3: Warm the Roast Beef
Simmer beef broth in a skillet. Separate roast beef slices and warm in the broth for 1–2 minutes.
Step 4: Assemble the Sandwiches
Spread Arby’s sauce on bun bottoms, layer with roast beef, drizzle with cheese sauce, and top with the remaining buns.
