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Homemade Beef and Cheddar sandwich with sliced roast beef, cheddar cheese sauce and Arby's-style sauce on an onion roll

Homemade Beef and Cheddar Sandwiches

These homemade Beef and Cheddar sandwiches start with real oven-roasted top round, sliced thin and warmed in a savory au jus. Pile the juicy beef onto onion rolls with tangy homemade Arby's-style sauce and a smooth, creamy cheddar cheese sauce for a homemade version of the fast-food favorite.
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Prep Time 20 minutes
Cook Time 1 hour 10 minutes
Rest Time 20 minutes
Servings: 8 sandwhiches
Course: Main Course
Cuisine: American
Ingredients Method Notes

Ingredients
  

For the Roast Beef
  • - 3 lb top round beef roast
  • - 2 Tbsp olive oil
  • - 1/2 Tbsp salt
  • - 1/2 Tbsp black pepper
  • - 1/2 Tbsp garlic powder
  • - 1/2 tsp onion powder
For the Au Jus
  • - 1 1/2 cups beef broth
  • - 1 tsp beef base such as Better Than Bouillon
  • - 1 tsp Worcestershire sauce
  • - 1/4 tsp garlic powder
  • - 1/4 tsp onion powder
For the Arby's-Style Sauce
  • - 1/2 cup ketchup
  • - 2 Tbsp water
  • - 1 Tbsp apple cider vinegar
  • - 1 Tbsp brown sugar
  • - 1 tsp Worcestershire sauce
  • - 1/2 tsp onion powder
  • - 1/2 tsp garlic powder
  • - 1/4 tsp paprika
  • - 1/4 tsp salt
  • - 1/8 tsp black pepper
  • - Pinch of cayenne pepper optional
For the Cheddar Cheese Sauce
  • - 2 Tbsp butter
  • - 2 Tbsp all-purpose flour
  • - 1 cup whole milk
  • - 3 oz American cheese torn or chopped
  • - 3 oz mild cheddar cheese freshly shredded
  • - 1/4 tsp salt or to taste
For the Sandwiches
  • - 6–8 onion rolls

Method
 

Roast the Beef
  1. Preheat the oven to 475°F.
  2. Pat the top round roast dry with paper towels.
  3. Rub the roast all over with the olive oil. Season evenly with the salt, black pepper, garlic powder, and onion powder.
  4. Place the roast in an uncovered Dutch oven or roasting pan.
  5. Roast at 475°F for 20 minutes.
  6. Reduce the oven temperature to 300°F and continue roasting until the center reaches 125–130°F for medium-rare or about 135°F for medium. Begin checking the temperature early since cooking time will vary depending on the shape and thickness of the roast.
  7. Remove the roast from the oven and let it rest for at least 20 minutes.
  8. For easier slicing, allow the roast to cool further or refrigerate it for a couple of hours before slicing.
Make the Au Jus
  1. If there is a large amount of fat in the Dutch oven or roasting pan, spoon off the excess while leaving the browned bits behind.
  2. Add the beef broth, beef base, Worcestershire sauce, garlic powder, and onion powder.
  3. Place over medium heat and bring to a gentle simmer, scraping the bottom of the pan to loosen the browned bits.
  4. Simmer for 3–5 minutes.
  5. Taste before adding any additional salt. Keep warm until you're ready to heat the sliced beef.
Make the Arby's-Style Sauce
  1. Add the ketchup, water, apple cider vinegar, brown sugar, Worcestershire sauce, onion powder, garlic powder, paprika, salt, black pepper, and optional cayenne to a small saucepan.
  2. Whisk until combined.
  3. Bring to a gentle simmer over medium-low heat.
  4. Cook for 5–8 minutes, stirring occasionally, until slightly thickened and the flavors have combined.
  5. Remove from the heat and set aside.
Make the Cheddar Cheese Sauce
  1. Melt the butter in a small saucepan over medium-low heat.
  2. Whisk in the flour and cook for 1 minute, whisking constantly. Do not brown the roux.
  3. Slowly whisk in the whole milk.
  4. Cook for 2–4 minutes, whisking frequently, until the mixture begins to thicken.
  5. Reduce the heat to low. Add the American cheese and stir until completely melted.
  6. Add the mild cheddar a little at a time, stirring until smooth before adding more.
  7. Taste and add salt as needed.
  8. Keep the sauce warm over very low heat. If it becomes too thick, whisk in a small amount of warm milk until smooth and pourable.
Slice and Warm the Beef
  1. Determine which direction the grain runs through the roast.
  2. Using a sharp knife, slice the roast as thinly as possible across the grain.
  3. Heat the au jus until steaming, then reduce the heat to very low or remove it from the heat.
  4. Add the sliced beef to the hot au jus and gently toss just until the meat is warmed through. Do not boil or simmer the sliced beef.
Assemble the Sandwiches
  1. Lightly toast the onion rolls, if desired.
  2. Spread Arby's-style sauce over the bottom half of each onion roll.
  3. Pile plenty of warm roast beef onto each roll.
  4. Spoon the warm cheddar cheese sauce generously over the beef.
  5. Add the top bun and serve immediately with additional red sauce on the side.

Notes

- Cook by temperature, not just time. The thickness and shape of a top round roast can significantly affect cooking time.
- Don't overcook the roast. Remember that the sliced beef will be warmed again in the au jus before serving.
- Cooler beef is easier to slice thinly. If you have time, roast the beef earlier in the day and refrigerate it before slicing.
- Always slice across the grain for more tender roast beef.
- Don't simmer the sliced beef. The hot au jus is only being used to warm and moisten the already-cooked meat.
- Save the browned bits. Making the au jus directly in the Dutch oven or roasting pan gives it extra beef flavor.
- Keep the cheese sauce over low heat. Boiling can cause the cheese sauce to become grainy or separate.
- If the cheese sauce thickens, whisk in warm milk a tablespoon at a time until it becomes pourable again.
- The red sauce should be tangy, not overly sweet. The brown sugar is there to balance the vinegar rather than turn the sauce into barbecue sauce.
- Make ahead: The roast and Arby's-style sauce can be prepared earlier in the day. Wait to warm the sliced beef and make or reheat the cheddar sauce until shortly before serving.