Homemade Beef and Cheddar Sandwiches

These homemade Beef and Cheddar sandwiches have everything I love about the fast-food favorite, but we’re making them at home with real oven-roasted beef. Thinly sliced roast beef is warmed in a savory au jus, piled onto soft onion rolls, and topped with a tangy homemade Arby’s-style sauce and plenty of creamy cheddar cheese sauce.

The trick was making sure these tasted like a Beef and Cheddar and not just a roast beef sandwich with cheese on top. Starting with a top round roast gives us slices of actual roast beef, while warming those thin slices briefly in a flavorful beef jus keeps them tender and juicy. Add the tangy red sauce and warm cheddar sauce, and that’s where the familiar Beef and Cheddar flavor really comes together.

These take a little more work than pulling through the drive-thru, but almost everything can be prepared ahead of time. And once that warm roast beef, tangy sauce, and creamy cheese hit an onion roll together, it’s absolutely worth it.

Quick Answer

How do you make a homemade Beef and Cheddar sandwich?

Start by roasting a seasoned top round roast until medium, let it rest, and slice it very thinly across the grain. Make a simple au jus from beef broth and the browned drippings left in the roasting pan, then briefly warm the sliced beef in the hot jus.

Pile the warm roast beef onto an onion roll and top it with a tangy homemade Arby’s-style sauce and creamy cheddar cheese sauce. The combination of thinly sliced juicy beef, onion roll, tangy red sauce, and warm cheese sauce gives you that familiar Beef and Cheddar flavor at home.

Why You’ll Love These Beef and Cheddar Sandwiches

• They have that familiar Beef and Cheddar flavor. The combination of tender roast beef, tangy Arby’s-style sauce, creamy cheddar sauce, and an onion roll is what really brings these sandwiches together.
• We’re using real oven-roasted beef. Instead of deli roast beef, a top round roast is simply seasoned and roasted, then sliced thin for hearty homemade sandwiches.
• The beef stays tender and juicy. Briefly warming the thinly sliced roast beef in homemade au jus adds moisture and plenty of beefy flavor without overcooking it.
• Both sauces are homemade. The tangy red sauce takes just a few minutes on the stovetop, and the creamy cheddar sauce is made from scratch with mild cheddar and American cheese for a smooth, pourable texture.
• You can prepare several components ahead of time. Roast the beef and make the red sauce earlier in the day, then slice and warm the beef and make the cheddar sauce when you’re ready to eat.
• They’re perfect with homemade fries. Add a pile of crispy fries on the side and you’ve got your own Beef and Cheddar night at home.

Ingredients You’ll Need

There are three main parts to these homemade Beef and Cheddar sandwiches: the roast beef and au jus, tangy Arby’s-style sauce, and creamy cheddar cheese sauce. None of the individual components are difficult, and together they’re what give these sandwiches that familiar flavor.

Top Round Roast

I use a 3-pound top round roast for these sandwiches. Top round is leaner than chuck roast and works especially well when you want actual slices of roast beef rather than shredded beef.

The roast is cooked just until medium, rested, and then sliced as thinly as possible across the grain. Letting the roast cool before slicing makes getting those thin slices much easier.

Olive Oil

A little olive oil helps the seasonings stick evenly to the outside of the roast and encourages browning during the initial high-temperature roast.

Salt, Pepper, Garlic Powder, and Onion Powder

I keep the seasoning on the beef intentionally simple.

We’re not trying to turn this into a heavily seasoned pot roast. The roast beef should be savory and beefy while letting the au jus, tangy red sauce, cheddar sauce, and onion roll create the signature flavor of the sandwich.

Beef Broth

Beef broth forms the base of the au jus and helps loosen all those flavorful browned bits left behind after roasting the beef.

If you roast the beef in a Dutch oven or roasting pan, don’t scrub it out before making the au jus. Those browned bits on the bottom are packed with flavor.

Beef Base

A small amount of beef base, such as Better Than Bouillon, gives the au jus a deeper beef flavor without requiring hours of simmering.

Taste the jus before adding any additional salt since the beef base and broth can both be fairly salty.

Worcestershire Sauce

A little Worcestershire adds savory depth to the au jus without making it taste like pot roast.

It also appears in the homemade red sauce, where its tangy, savory flavor helps balance the sweetness of the ketchup and brown sugar.

Ketchup

Ketchup is the base of the homemade Arby’s-style sauce. It gives us tomato flavor, sweetness, and the familiar red color.

Once vinegar, Worcestershire, and seasonings are added, the finished sauce becomes much tangier and more savory than plain ketchup.

Apple Cider Vinegar

Apple cider vinegar gives the red sauce the tanginess it needs and keeps it from becoming overly sweet.

That little bit of acidity is especially good against the rich beef and creamy cheese sauce.

Brown Sugar

Just a tablespoon of brown sugar rounds out the acidity in the red sauce.

The goal isn’t a sweet barbecue-style sauce. You only need enough sweetness to balance the ketchup and vinegar while keeping the finished sauce noticeably tangy.

Butter and All-Purpose Flour

Butter and flour make a simple roux for the cheddar sauce.

The roux gives the sauce enough body to cling to the beef while still keeping it loose enough to pour over the sandwich.

Whole Milk

Whole milk keeps the cheddar sauce creamy without making it overly heavy.

If the cheese sauce becomes thicker than you’d like as it sits, whisk in a splash of warm milk until it’s pourable again.

Mild Cheddar Cheese

Mild cheddar gives the sauce plenty of cheddar flavor without overpowering the roast beef and red sauce.

Freshly shredded cheese will generally melt more smoothly than pre-shredded cheese.

American Cheese

This is one ingredient I wouldn’t skip.

American cheese contains emulsifiers that help the cheddar sauce stay smooth, creamy, and pourable instead of becoming oily or grainy.

We’re still getting plenty of real cheddar flavor from the mild cheddar. The American cheese is here to help give us that silky cheese-sauce texture.

Onion Rolls

The onion roll isn’t just holding everything together. Its slightly sweet onion flavor is an important part of what makes the finished sandwich taste like a Beef and Cheddar.

Lightly toast the rolls just before assembling so they’re warm and sturdy enough to hold all that juicy beef and cheese sauce.

How to Make Homemade Beef and Cheddar Sandwiches

These sandwiches have a few different components, but each one is simple to make. You can also prepare the roast beef and Arby’s-style sauce ahead of time, then make the cheddar sauce and warm the beef when you’re ready to eat.

1. Season the Beef

Preheat the oven to 475°F.

Pat a 3-pound top round roast dry with paper towels.

Rub the roast all over with 2 tablespoons olive oil, then season evenly with salt, black pepper, garlic powder, and onion powder.

Place the roast in an uncovered Dutch oven or roasting pan.

2. Roast the Beef

Roast the beef uncovered at 475°F for 20 minutes.

Reduce the oven temperature to 300°F and continue roasting until the center reaches your desired temperature.

For tender roast beef that will be reheated briefly in the au jus later, I recommend removing the roast around 125–130°F for medium-rare or around 135°F for medium.

Start checking the internal temperature early rather than relying only on cooking time. The thickness and shape of the roast can make a big difference in how quickly it cooks.

Remove the roast from the oven and let it rest for at least 20 minutes before slicing.

If you have extra time, let the roast cool longer or refrigerate it for a couple of hours. A cooler roast is much easier to slice very thinly.

3. Make the Au Jus

Don’t clean out that Dutch oven yet!

If there is a large amount of rendered fat in the pan, spoon off the excess while leaving the browned bits behind.

Add the beef broth, beef base, Worcestershire sauce, garlic powder, and onion powder directly to the Dutch oven.

Place over medium heat and bring to a gentle simmer, scraping the bottom of the pan to loosen all those flavorful browned bits.

Simmer for 3–5 minutes, then reduce the heat to low.

Taste before adding any additional salt. Between the beef drippings, broth, Worcestershire sauce, and beef base, you may not need any.

4. Make the Arby’s-Style Sauce

In a small saucepan, whisk together the ketchup, water, apple cider vinegar, brown sugar, Worcestershire sauce, onion powder, garlic powder, paprika, salt, black pepper, and a tiny pinch of cayenne if you’d like a little heat.

Bring the mixture to a gentle simmer over medium-low heat.

Cook for 5–8 minutes, stirring occasionally, until the flavors have come together and the sauce has thickened slightly.

Remove from the heat and set aside.

The finished sauce should be tangy with just enough sweetness to balance it, rather than tasting like a sweet barbecue sauce.

5. Make the Cheddar Cheese Sauce

Melt the butter in a small saucepan over medium-low heat.

Whisk in the flour and cook for about 1 minute, stirring constantly. Don’t let the roux brown.

Slowly whisk in the whole milk.

Cook for 2–4 minutes, whisking frequently, until the mixture begins to thicken slightly.

Reduce the heat to low and add the American cheese. Stir until completely melted.

Add the mild cheddar a little at a time, stirring until smooth before adding more.

Taste and season with salt as needed.

The finished cheddar sauce should be smooth and pourable rather than thick. If it becomes too thick while sitting, whisk in a tablespoon of warm milk at a time until it reaches the consistency you want.

Don’t allow the cheese sauce to boil after adding the cheese.

6. Slice the Roast Beef

Once the roast has rested and cooled enough to handle, determine which direction the grain is running.

Using a sharp knife, slice the beef as thinly as possible across the grain.

Cutting across the grain is important because it shortens the muscle fibers and makes each slice much more tender.

7. Warm the Beef in the Au Jus

Bring the au jus back to steaming hot, then reduce the heat to very low or remove the pan from the heat.

Add the thinly sliced roast beef to the hot jus just long enough to warm it through.

Don’t simmer or boil the sliced beef. It’s already cooked, and leaving it in the hot liquid too long can take tender roast beef and make it overdone.

8. Toast the Onion Rolls

Lightly toast the onion rolls just before assembling the sandwiches.

You want them warm with a little structure around the edges while still staying soft enough for a classic Beef and Cheddar-style sandwich.

9. Assemble the Beef and Cheddar Sandwiches

Spread a generous spoonful of the homemade Arby’s-style sauce over the bottom half of each onion roll.

Pile on plenty of warm, thinly sliced roast beef.

Spoon the warm cheddar cheese sauce over the beef, then add the top half of the onion roll.

Serve immediately with extra red sauce on the side and a pile of crispy fries.

Tips for the Best Beef and Cheddar Sandwiches

There are a few moving parts to homemade Beef and Cheddar sandwiches, but none of them are difficult. These tips will help keep the roast beef tender, the cheese sauce creamy, and everything hot when it’s time to assemble.

Use a Meat Thermometer for the Roast

Cooking time is only a guide when you’re roasting beef. Two 3-pound roasts can cook differently depending on their shape and thickness.

Use an instant-read thermometer and start checking the roast earlier than you think you’ll need to. Since the sliced beef will be warmed again in the au jus, you don’t want to overcook it in the oven.

Let the Beef Cool Before Slicing

You can slice the roast after its 20-minute rest, but if you have time to let it cool longer, even better.

Cool beef is firmer and much easier to slice thinly than a piping-hot roast. You can even roast the beef earlier in the day and refrigerate it until you’re ready to make the sandwiches.

Always Slice Across the Grain

Before slicing, take a minute to look at the roast and determine which direction the muscle fibers are running.

Slice across those fibers rather than in the same direction. This makes a big difference in how tender the finished roast beef feels when you bite into the sandwich.

Slice the Beef as Thinly as You Can

You don’t need a deli slicer to make these sandwiches.

Use your sharpest knife and make the slices as thin as you comfortably can. Once they’re briefly warmed in the au jus, they’ll become even softer and juicier.

Save Those Browned Bits

If you’re roasting the beef in a Dutch oven or roasting pan, don’t wash the pan before making the au jus.

The browned bits left behind from roasting the beef add a ton of flavor. Adding the broth directly to the pan and scraping those bits from the bottom gives you a much richer au jus with very little extra work.

Don’t Boil the Sliced Beef

The roast beef is already cooked before it goes into the au jus.

Get the jus hot, then gently warm the thinly sliced beef in it just before assembling the sandwiches. Boiling or simmering the beef for too long can continue cooking it and make a lean top round roast tougher and drier.

Keep the Cheddar Sauce on Low Heat

Once the cheese has been added, don’t let the sauce boil.

Low heat helps keep the cheddar sauce smooth and creamy. If it thickens while you’re waiting to assemble the sandwiches, whisk in a splash of warm milk until it’s pourable again.

Don’t Skip the American Cheese

The American cheese isn’t there to replace the cheddar. It helps the cheddar melt into a silky, smooth sauce that stays creamy instead of becoming grainy or oily.

You’ll still get the cheddar flavor, just with a much better texture for pouring over the roast beef.

Make the Red Sauce Ahead

The homemade Arby’s-style sauce is an easy component to knock out ahead of time.

Make it earlier in the day or even the day before, refrigerate it in a covered container, and gently warm it when you’re ready to assemble the sandwiches.

Get Everything Ready Before Warming the Beef

Once the beef goes into the hot au jus, you’re only a few minutes away from eating.

Have the onion rolls toasted, red sauce ready, and cheddar sauce warm before you add the sliced beef to the jus. That way the beef goes straight from the pan to the sandwich while it’s still hot and juicy.

Serve Them Right Away

These sandwiches are at their best freshly assembled while the beef and cheese sauce are hot and the toasted onion rolls haven’t had time to soften too much from the sauces.

Pile on the beef, don’t be shy with the cheddar sauce, and have plenty of napkins nearby. This isn’t exactly a neat little sandwich, and that’s half the fun.

Variations and Substitutions

The homemade roast beef, tangy red sauce, and creamy cheddar sauce are what make these sandwiches special, but there are a few easy substitutions you can make depending on what you have and how much time you want to spend in the kitchen.

Can I Use Deli Roast Beef?

Absolutely. If you want a much quicker version, use thinly sliced deli roast beef instead of roasting a top round.

Make the au jus as directed without the pan drippings, then gently warm the deli roast beef in the hot jus just before assembling the sandwiches.

It’s a great shortcut for a busy weeknight, although roasting the beef yourself gives you more control over the flavor and doneness.

Can I Use a Different Beef Roast?

Top round works especially well because it can be roasted to medium or medium-rare and sliced thinly for sandwiches.

You can also use another roast that’s suitable for traditional roast beef, such as eye of round or sirloin tip roast. Cooking times will vary, so use the internal temperature rather than the clock to determine when the roast is ready.

I wouldn’t substitute chuck roast if you want the same thinly sliced roast beef texture. Chuck is better suited to long, slow cooking and shredding.

What Can I Use Instead of Onion Rolls?

Onion rolls give these sandwiches that familiar Beef and Cheddar flavor, so they’re my first choice.

If you can’t find them, try a soft sandwich roll, sesame seed bun, brioche bun, or another sturdy but soft hamburger-style roll.

Can I Use a Different Cheese?

Mild cheddar and American cheese give the sauce a creamy texture and mild cheddar flavor.

You can substitute medium cheddar for a slightly stronger cheese flavor. I wouldn’t use only aged sharp cheddar because it can be more difficult to melt into a perfectly smooth sauce.

Make It Extra Saucy

If you’re a sauce person, make a double batch of the Arby’s-style sauce and serve the extra alongside the sandwiches for dipping.

You can also spoon a little au jus onto the beef before adding the cheddar sauce, but don’t soak the bun or it may become soggy.

Make Smaller Beef and Cheddar Sliders

Use small onion or slider rolls instead of full-size sandwich rolls.

Pile each one with warm roast beef, red sauce, and cheddar sauce for an easy game-day or party version of these sandwiches.

Keep the beef and sauces warm separately and assemble the sliders shortly before serving so the rolls don’t get soggy.

How to Store and Reheat Beef and Cheddar Sandwiches

If you have leftovers, store the individual components separately rather than refrigerating fully assembled sandwiches. This keeps the onion rolls from getting soggy and makes it much easier to reheat the beef without overcooking it.

How to Store Leftovers

Store the sliced roast beef in an airtight container in the refrigerator for up to 3–4 days.

Keep some of the au jus with the beef or store it in a separate covered container. Having that extra jus makes reheating the roast beef much easier without drying it out.

Store the Arby’s-style sauce and cheddar cheese sauce in separate airtight containers in the refrigerator.

Keep the onion rolls at room temperature in their original package or another airtight container.

How to Reheat the Roast Beef

Warm the au jus in a saucepan or Dutch oven over medium-low heat until steaming.

Reduce the heat to low or remove the pan from the heat, then add the sliced roast beef just long enough to warm through.

Avoid boiling the beef. Since the roast is already cooked, prolonged reheating can make a lean cut like top round dry and tough.

How to Reheat the Cheddar Sauce

Reheat the cheddar sauce gently in a small saucepan over low heat, stirring frequently.

The sauce will thicken considerably after refrigeration. Whisk in a splash of milk as it warms until it becomes smooth and pourable again.

Avoid boiling the cheese sauce.

How to Reheat the Arby’s-Style Sauce

The red sauce can be served cool, at room temperature, or gently warmed in a small saucepan over low heat.

If it becomes thicker after refrigeration, stir in a small splash of water until it reaches the consistency you like.

Assemble After Reheating

Lightly toast fresh onion rolls while the beef and sauces are warming.

Then assemble each sandwich with red sauce, warm roast beef, and plenty of cheddar sauce.

Keeping everything separate until you’re ready to eat means your leftover Beef and Cheddar can be almost as good as the first one.

Frequently Asked Questions

What Cut of Beef Is Best for Homemade Beef and Cheddar Sandwiches?

I like top round roast for homemade Beef and Cheddar sandwiches because it’s a traditional roast beef cut that can be cooked to medium or medium-rare and sliced thinly.

It’s leaner than chuck roast and gives these sandwiches more of a classic roast beef texture rather than shredded or pot-roast-style beef.

Can I Use Deli Roast Beef?

Yes. Thinly sliced deli roast beef is a great shortcut if you don’t want to roast the beef yourself.

Make the au jus, get it steaming hot, then gently warm the deli roast beef in the liquid just before assembling the sandwiches. Don’t boil the meat or leave it simmering in the jus.

How Do I Slice Roast Beef Thin Without a Meat Slicer?

Let the roast cool before slicing and use a very sharp knife.

Cooling firms up the beef and makes thin slices much easier to cut. Always slice across the grain for the most tender results.

If you have time, you can roast the beef earlier in the day and refrigerate it before slicing.

Why Do You Warm the Roast Beef in Au Jus?

Top round is a relatively lean cut of beef. Briefly warming the thin slices in hot au jus adds moisture and beefy flavor without requiring the roast to cook any longer than necessary.

The key is to warm the beef gently rather than simmering it.

What Is on a Beef and Cheddar Sandwich?

This homemade version is made with thinly sliced roast beef, tangy Arby’s-style sauce, creamy cheddar cheese sauce, and an onion roll.

The combination of the red sauce, warm cheddar sauce, and onion roll is what gives the sandwich its familiar Beef and Cheddar-style flavor.

Is Arby’s Sauce the Same as Barbecue Sauce?

Not quite. Arby’s-style sauce is tomato-based, but it’s generally thinner and tangier than traditional barbecue sauce.

For this homemade version, ketchup is combined with apple cider vinegar, Worcestershire sauce, brown sugar, and seasonings to make a sauce that’s tangy with just a little sweetness.

Why Is There American Cheese in the Cheddar Sauce?

American cheese helps create a smooth, creamy, pourable cheese sauce.

We’re still using mild cheddar for cheddar flavor, but the emulsifiers in American cheese help the sauce stay smooth instead of separating or becoming grainy.

Can I Make Beef and Cheddar Sandwiches Ahead of Time?

You can prepare most of the components ahead, but I recommend waiting to assemble the sandwiches until you’re ready to eat.

The roast beef and Arby’s-style sauce can be made ahead and refrigerated. When it’s time for dinner, make or reheat the cheddar sauce, warm the sliced beef briefly in the au jus, toast the onion rolls, and assemble.

What Temperature Should I Cook Top Round Roast To?

For these sandwiches, I recommend removing the roast at approximately 125–130°F for medium-rare or around 135°F for medium.

The roast will continue to rise slightly in temperature as it rests, and the sliced beef will later be warmed briefly in hot au jus.

Use an instant-read meat thermometer rather than relying only on cooking time because the shape and thickness of the roast can affect how quickly it cooks.

What Should I Serve With Beef and Cheddar Sandwiches?

Crispy homemade fries are the obvious choice and make these sandwiches feel like a complete Beef and Cheddar night at home.

You could also serve them with onion rings, potato wedges, coleslaw, potato salad, or a simple green salad.

Helpful Tools

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You don’t need any special equipment to make homemade Beef and Cheddar sandwiches, but a few basic kitchen tools make the roast easier to cook and slice.

Dutch Oven or Roasting Pan – I used a Dutch oven to roast the beef, and it worked especially well because I could make the au jus right in the same pot afterward.

Don’t clean out those browned bits after roasting the beef. Adding the broth directly to the Dutch oven and scraping up the bottom gives the au jus even more flavor.

Instant-Read Meat Thermometer – A meat thermometer is one tool I definitely recommend for this recipe.

Top round is fairly lean, so cooking the roast to temperature rather than relying only on time helps prevent it from becoming overdone. Start checking early and remove the roast when it reaches your preferred doneness.

Carving Knife – A sharp knife makes it much easier to get thin slices of roast beef.

Letting the roast cool before slicing also helps. Remember to slice across the grain for the most tender beef.

Small Saucepans – You’ll need small saucepans for the Arby’s-style sauce and cheddar cheese sauce. Having both sauces ready before warming the sliced beef makes final assembly much easier.

More Easy Dinner Recipes

If you’re looking for more hearty family dinners, here are a few more favorites from The Pickled Farmhouse.

• Salisbury Steak with Mushroom Gravy – Homemade Salisbury steaks smothered in a rich mushroom and onion gravy for an easy comfort-food dinner.
• Homemade Sloppy Joes – A saucy ground beef sandwich that’s easy enough for a busy weeknight and made completely from scratch.
• Creamy Mac and Cheese – Rich, creamy homemade mac and cheese that makes an easy side for sandwiches or a comforting dinner all by itself.