A few weeks ago, my husband and I were out running errands—nothing exciting, just groceries, oil change, and picking up our daughter from rehearsal. It was one of those nonstop afternoons that leave everyone cranky and hungry. As we passed a drive-thru, he joked, “If I had an Arby’s Beef and Cheddar right now, I’d do the rest of these errands with a smile.”
I laughed it off, but the idea stuck with me. Not because of the sandwich itself, but because that combo of warm roast beef, tangy sauce, and melty cheese held some nostalgic weight for both of us. So I made a little challenge for myself: recreate it at home, but make it feel a little fresher, a little more like something I’d want to feed the kids on a weeknight without feeling guilty.
By the time the sandwiches were plated—buns soft and warm, cheese sauce oozing just enough, and that signature sweet-tangy Arby’s-style sauce dripping down the side—he took one bite and just said, “You nailed it.” No sandwich has ever gone that fast in our house. Even my picky eater son didn’t ask what was in it.
Now it’s in regular rotation, and I have to say, I kind of look forward to those errand days a little more.
Short Description
This Arby’s Beef and Cheddar Copycat sandwich layers warm deli roast beef, homemade cheddar cheese sauce, and tangy Arby’s-style sauce on a soft onion bun. A fast, satisfying classic made right at home.
Key Ingredients
For the Arby’s Sauce:
- ½ cup ketchup
- 2 tbsp light brown sugar, packed
- 1 tbsp apple cider vinegar
- 1 tbsp Worcestershire sauce
- ½ tsp garlic powder
- ½ tsp onion powder
For the Cheese Sauce:
- 1 tbsp unsalted butter
- 1 tbsp all-purpose flour
- 1 cup whole milk
- 6 oz shredded sharp cheddar cheese
For the Sandwich Assembly:
- 2 cups low sodium beef broth
- 1 lb thinly sliced deli roast beef
- 4 onion hamburger buns
Tools Needed
- Small mixing bowl
- Saucepan
- Whisk
- Large skillet
- Tongs
- Ladle or spoon
Cooking Instructions
Step 1: Make the Arby’s Sauce
In a small bowl, whisk together ketchup, brown sugar, vinegar, Worcestershire, garlic powder, and onion powder until smooth. Set aside.
Step 2: Make the Cheese Sauce
In a small saucepan, melt butter over medium heat. Stir in flour and cook for 1 minute, stirring constantly. Slowly whisk in milk, then bring to a gentle simmer for about 5 minutes. Remove from heat and stir in shredded cheese until smooth and creamy.
Step 3: Warm the Roast Beef
In a large skillet over medium heat, bring beef broth to a simmer. Add roast beef slices one at a time to separate them. Warm for 1–2 minutes until heated through.
Step 4: Assemble the Sandwiches
Spread Arby’s sauce on the bottom bun. Layer on warm roast beef, spoon over cheese sauce, and top with the other half of the bun. Serve immediately while hot.
Why You’ll Love This Recipe
Flavor Explosion: Sweet and tangy sauce with creamy cheese and juicy beef hits all the right notes.
Quick and Easy: Comes together in 20 minutes—perfect for busy nights.
Family Favorite: Both adults and kids love it (no complaints at the dinner table!).
Customizable: Use different cheeses or buns to suit your taste.
No Drive-Thru Needed: Skip the fast food line and make it fresher at home.
Mistakes to Avoid & Solutions
Lumpy Cheese Sauce: Happens if the flour isn’t cooked enough or milk added too fast.
Solution: Stir the flour-butter mixture constantly and add milk slowly while whisking.
Rubbery Roast Beef: Overheating in broth can toughen the meat.
Solution: Just warm for 1–2 minutes in simmering broth, not boiling.
Watery Sauce: If the cheese sauce feels thin.
Solution: Let it simmer longer before adding cheese or add more cheese to thicken.
Overly Sweet Sauce: Brown sugar and ketchup can be intense together.
Solution: Taste before assembling—adjust vinegar or Worcestershire to balance.
Soggy Buns: Can happen if too much sauce is used or buns sit too long.
Solution: Toast the buns lightly or serve immediately after assembly.
Serving and Pairing Suggestions
Serve hot with curly fries, sweet potato fries, or onion rings.
Add a side salad or coleslaw for a refreshing contrast.
Great for casual weeknight dinners, game day spreads, or fun weekend lunches.
For a crowd, lay out toppings and let guests assemble their own sandwiches buffet-style.
Storage and Reheating Tips
To Store: Store leftover roast beef, sauces, and buns separately in airtight containers.
Refrigeration: Keep in fridge for up to 3 days.
To Reheat Beef: Warm gently in simmering broth or microwave with a splash of broth.
To Reheat Cheese Sauce: Reheat slowly on the stove or in the microwave in 15-second intervals, stirring each time.
Do Not Assemble Ahead: Assemble only when ready to serve to avoid soggy buns.
FAQs
1. Can I use another cheese besides cheddar?
Yes! American cheese, Monterey Jack, or pepper jack all melt beautifully.
2. What if I don’t have onion buns?
Any soft hamburger bun works—try brioche or potato buns for a twist.
3. Can I make the sauces ahead of time?
Absolutely. Both the Arby’s sauce and cheese sauce can be made up to 3 days in advance.
4. Is deli roast beef the same as what Arby’s uses?
Close enough! Just be sure it’s sliced thin and low-sodium works best for flavor balance.
5. Can I freeze this sandwich?
Not recommended. The cheese sauce texture may separate after freezing. Freeze just the beef if needed.
Tips & Tricks
Use pre-shredded cheese for convenience, but block cheese melts creamier if you have time to shred it.
Toast the buns slightly for better texture and to help them hold up to the sauce.
For extra kick, add a few dashes of hot sauce to the Arby’s sauce.
Want extra cheesy? Double the cheese sauce and serve a little on the side for dipping.
Add sautéed onions or banana peppers for an extra layer of flavor.
Recipe Variations
Spicy Beef and Cheddar: Add jalapeños or use pepper jack in the cheese sauce.
Flavor Profile: Creamy heat with a tangy edge.
BBQ Beef and Cheddar: Replace Arby’s sauce with your favorite barbecue sauce.
Flavor Profile: Smoky-sweet with melty cheese comfort.
Horseradish Cheddar Melt: Stir prepared horseradish into the cheese sauce.
Flavor Profile: Zesty, sharp, and bold.
French Onion Twist: Add caramelized onions and a splash of beef broth over the beef before topping with cheese.
Flavor Profile: Rich, savory, and slightly sweet.
Final Thoughts
Homemade doesn’t always mean complicated, it just means thoughtful. Watching my husband take that first bite with raised eyebrows, then hearing “You should open a sandwich truck” from my daughter, was all the feedback I needed.
The leftovers disappeared before lunch the next day, and my son asked if we could do them again “but with bacon next time.” Challenge accepted. Meals like this turn regular weeknights into a little something special without needing reservations—or drive-thru bags.
Arby's Beef And Cheddar Copycat
Ingredients
For the Arby’s Sauce:
- ½ cup ketchup
- 2 tbsp light brown sugar packed
- 1 tbsp apple cider vinegar
- 1 tbsp Worcestershire sauce
- ½ tsp garlic powder
- ½ tsp onion powder
For the Cheese Sauce:
- 1 tbsp unsalted butter
- 1 tbsp all-purpose flour
- 1 cup whole milk
- 6 oz shredded sharp cheddar cheese
For the Sandwich Assembly:
- 2 cups low sodium beef broth
- 1 lb thinly sliced deli roast beef
- 4 onion hamburger buns
Instructions
- Whisk together ketchup, brown sugar, vinegar, Worcestershire, garlic powder, and onion powder. Set aside.
- Melt butter in a saucepan over medium heat. Stir in flour and cook 1 minute. Whisk in milk and simmer for 5 minutes. Remove from heat, stir in cheese until smooth.
- Simmer beef broth in a skillet. Add roast beef slices and warm for 1–2 minutes.
- Spread Arby’s sauce on buns, add warm beef, top with cheese sauce, and close with top bun. Serve hot.
