Smoked Beef and Cheddar Sandwiches with Arby’s-Style Sauce

Copycat Arby’s Beef ‘N Cheddar with Oak-Smoked Roast Beef

Arby’s may have the meats, but they don’t have smoke like this. Growing up, the Beef ‘n Cheddar was the go-to fast food sandwich—soft bun, sweet tangy sauce, molten cheese, and shaved roast beef stacked high. But once I started making my own deli-style smoked roast beef at home, I knew I had to reimagine this favorite with real ingredients and bold barbecue flavor. We start with eye of round seasoned with Revolution Barbecue Texas Beef BBQ Rub, smoked over oak, then chilled and sliced paper thin. The sauce is a nod to the original—sweet, tangy, and spiced just right with hot sauce and cider vinegar. And the cheddar? No shortcuts here. We’re making a real cheese sauce with sharp cheddar, American slices, and whole milk that drapes over the meat like velvet. Served on a soft sesame-seeded bun, this sandwich keeps the fast-food soul but brings backyard BBQ attitude to the table. One bite and you’ll know—this one’s done right.

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