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This Arby's roast beef and cheddar sandwich recipe delivers the iconic toasted bun crunch and perfectly melted cheese layers you crave. The secret lies in thinly sliced roast beef that stays tender yet firm, combined with sharp cheddar cheese that melts into gooey perfection between each slice. I've perfected the technique to recreate that signature Arby's experience at home, where every bite delivers the right balance of savory, salty, and slightly sweet flavors.
What sets this recipe apart is the proper preparation of each component—grilling the buns until they develop that characteristic crispy exterior while staying soft inside, slicing the roast beef paper-thin for maximum tenderness, and layering the cheese so it melts evenly without turning rubbery. The process is straightforward but requires attention to detail to achieve authentic results. You'll need just 15 minutes of active prep time followed by 5 minutes of grilling, making it perfect for a quick yet satisfying lunch or dinner.
The final sandwich features a perfectly toasted bun with crispy edges that provide satisfying crunch, layers of tender roast beef that hold their shape, and melted cheddar cheese that creates a cohesive, flavorful bite. The combination of textures and flavors comes together to deliver that familiar Arby's taste you love, but with the flexibility to customize with optional toppings like dill pickle chips or Arby's signature sauce if you prefer.
This recipe serves as a complete meal experience, offering the option to pair your sandwich with classic sides like crispy fries or a fresh side salad. The key to success lies in proper temperature control and assembly timing—each element must come together in the right order to achieve that signature Arby's quality. Let's recreate this iconic sandwich at home with professional results.
Ingredients for arbys roast beef and cheddar cheese sandwich
Four key ingredients transform this into that iconic Arby's sandwich at home.
| Ingredient | Amount | Notes |
|---|---|---|
| Roast Beef 🥩 | 1 ½ lb | Paper-thinly sliced, high-quality |
| Sharp Cheddar Cheese 🧀 | 8 oz | Block form, freshly grated |
| Arby's Style Sesame Seed Buns 🍞 | 4 whole | Or sub with potato buns |
| Unsalted Butter 🧈 | 2 tbsp | Softened for toasting |
| Mayonnaise 🥫 | 2 tbsp | For optional spread |
| Dill Pickle Chips 🥒 | ¼ cup | Optional topping |
| Kosher Salt 🧂 | ½ tsp | For seasoning beef |
| Ground Black Pepper 🌶️ | ½ tsp | Freshly cracked |
| Garlic Powder 🧄 | ¼ tsp | For beef seasoning |
| Vegetable Oil 🫒 | 1 tbsp | For grilling buns |
| Arby's Signature Sauce 🍯 | 2 tbsp | Optional for dipping |
The roast beef is everything. Ask your butcher for top round or sirloin—it stays tender when sliced thin. I always grab pre-sliced deli roast beef from the grocery store meat counter (the kind that comes in a vacuum-sealed package), but if you're slicing yourself, aim for 1/8-inch thickness. Season it lightly with salt, pepper, and garlic powder—just enough to enhance, not overpower. The cheese? Sharp cheddar is non-negotiable—pre-shredded gets clumpy, so grate your own from a block. For the buns, Arby's-style sesame seed buns are ideal, but potato buns work too if you're in a pinch.
No Arby's sauce? Mix 1 tbsp mayo, 1 tsp yellow mustard, and 1 tsp honey for a quick sub. Pickle chips optional, but they add that signature tang. The butter matters for toasting—softened, not melted. Spread it on the cut sides of the buns and grill them until golden brown. Pro tip: Use a wire rack on a baking sheet to toast the buns so they get crispy all over. And if you're feeling fancy, lightly toast the cheese slices in the same butter for that extra-melty texture.
Prep ahead by slicing the beef and grating the cheese—both keep 3-4 days in the fridge. The buns stay fresh 2 days if wrapped tightly. Assemble sandwiches just before serving so the buns stay crispy. Leftovers? Wrap tightly in foil and reheat in a skillet with a little butter for 1-2 minutes per side—nothing beats a freshly toasted Arby's-style sandwich, but this keeps it close.
Why You'll Love This Recipe
- Five-Ingredient Magic: I swear by this combo—just roast beef, sharp cheddar, buttery buns, mayo, and a knife. Honestly, that’s it. No fancy prep, no hidden steps, just layering those ingredients like a sandwich artist. The cheddar melts into the beef while the sesame buns stay soft, and the mayo ties it all together without overpowering.
- That Crunchy-Creamy Bite: Between us, the real win is the texture: that crispy toasted bun edge with the gooey, pulled-apart cheddar center. I’ll be real, the first time I made this, I nearly burned the buns—now I watch them like a hawk. But that perfect contrast? It’s what makes this sandwich dangerously addictive.
- Lunchbox or Picnic Star: This is my go-to for meal prep because it holds up. Wrap halves in foil, and they stay fresh for days—no sad, soggy sandwiches here. Pack them for work, toss them in a cooler for a tailgate, or just eat them straight from the fridge. The beef stays tender, and the cheddar doesn’t slide out.
- Budget Hack That Feeds: A pound of roast beef and a block of cheddar stretch farther than you’d think. I make four sandwiches for under $10, and they’re heartier than takeout. Plus, leftovers? Just reheat the beef in the microwave, slap it on fresh buns, and boom—another meal with zero extra cost. My wallet thanks me every time.
Step-by-step instructions for Arby's roast beef and cheddar cheese sandwiches
Here's how to recreate that signature Arby's texture—crispy buns, perfectly sliced beef, and melty cheese layers.
Season and Slice the Roast Beef
Start by placing the 1.5 lb roast beef on a cutting board. Pat it dry with paper towels—this helps the seasoning stick and creates a better sear. In a small bowl, mix together the 0.5 tsp kosher salt, 0.5 tsp ground black pepper, and 0.25 tsp garlic powder. Rub this evenly over both sides of the beef.
Use a very sharp knife to slice the beef paper-thin, against the grain. You want slices that are almost translucent—this ensures they stay tender when assembled. The thinner the slices, the more authentic the sandwich will taste. Arrange the sliced beef on a plate and set aside while you prepare the other components.
Grill the Sesame Seed Buns
Heat a skillet over medium heat and add the 1 tbsp vegetable oil. Once the oil is shimmering, place the 4 whole Arby's Style Sesame Seed Buns in the pan. Grill each bun for 2-3 minutes per side until they develop a golden-brown crust and are toasted to perfection.
Here's the thing—don't rush this step. You want the buns to get that classic Arby's crunch. If they brown too quickly, reduce the heat slightly. Once toasted, remove the buns from the pan and place them on a wire rack to cool for 1-2 minutes before assembling. This prevents soggy sandwiches.
Assemble the Sandwiches
Take one of the toasted buns and spread 1 tbsp mayonnaise evenly on the inside surface. This isn't just for flavor—it acts as a glue to hold everything together. Layer 3-4 slices of the seasoned roast beef on top of the mayonnaise, slightly overlapping them if needed to cover the bun completely.
Next, sprinkle 2 tbsp of the freshly grated sharp cheddar cheese evenly over the beef. The cheese should be finely grated so it melts smoothly and creates those gooey layers. Place the second half of the bun on top, pressing down gently but not too hard—you want the cheese to melt slightly from the heat of the beef, not squish out.
Optional Additions and Serving
If you're using the 0.25 cup dill pickle chips, sprinkle them evenly over the top half of each sandwich. These add that signature tangy crunch that balances the richness of the beef and cheese. For an extra authentic touch, you can also serve the 2 tbsp Arby's Signature Sauce on the side for dipping.
Serve the sandwiches immediately while the cheese is still warm and melty. The combination of crispy buns, tender beef, and gooey cheese should give you that classic Arby's experience right at home. Enjoy with a side of fries or coleslaw for the full effect!
Pro Tips For Making Arbys Roast Beef And Cheddar Cheese Sandwich
- Slice Thin, Slice Even: I used to eyeball it and ended up with uneven layers—some sandwiches were dry, others soggy. Grab a sharp knife and slice the roast beef paper-thin, about ⅛-inch thick, and stack the slices neatly. This keeps the sandwich from falling apart when you toast it, and the beef stays juicy.
- Toast Buns Low and Slow: High heat burns the sesame seeds before the bun even gets warm. Instead, toast the buns on medium-low in a dry pan or toaster for 1-2 minutes per side—just until the bread is golden and the butter melts. You want the seeds to pop, not crisp into charcoal.
- Shred Cheese Fresh, Not Store-Bought: Pre-shredded cheddar has anti-caking agents that make it clump and lose moisture. Instead, grate sharp cheddar yourself right before assembling the sandwich—it melts smoother and sticks better to the beef. (Yes, it’s a pain, but it’s the thing that matters most.)
- Butter the Outside Only: Slathering butter inside the bun turns it into a greasy mess. Instead, melt the unsalted butter and brush it only on the outside of the toasted buns—just enough to glaze them. This keeps the interior soft while giving that classic Arby’s shine without making the sandwich greasy.
Make-ahead tips for leftovers
Prep Components Ahead
Slice the 1.5 lb roast beef paper-thin and grate the 8 oz sharp cheddar cheese up to 3 days in advance. Store both in airtight containers with parchment paper between layers to prevent sticking. The cheese will keep its sharpness, and the beef stays tender when refrigerated properly. This saves you 15 minutes of prep time when you're ready to assemble.
Toast Buns Early
Grill the sesame seed buns up to 2 hours ahead and store them at room temperature in a paper bag. The buns stay crispy for this time because they cool completely before storage. Reheat in a 350°F oven for 3-5 minutes to restore their crunch. I find this works better than keeping them warm in a toaster oven, which can dry them out.
Assemble Just Before Serving
Wait to assemble until you're ready to eat—this preserves that perfect crunch. Spread the 2 tbsp mayonnaise on the buns and layer the cheese between beef slices just before serving. The cheese melts best when assembled fresh, creating those signature gooey layers. If you must prep ahead, keep components separate until the last moment.
Freezer-Friendly Assembly
For meal prep, assemble sandwiches without cheese and freeze them unwrapped on a tray for 1 hour. Transfer to a freezer bag for up to 1 month. To serve, thaw in the fridge overnight, then toast in a skillet with 1 tbsp butter for 2 minutes per side. Add cheese fresh from the fridge for that perfect melt.
Reheat Leftovers Properly
Wrap leftover sandwiches in foil and reheat in a 375°F oven for 5-7 minutes to restore crispiness. For a faster method, use a skillet with 1 tbsp vegetable oil over medium heat for 1-2 minutes per side. The oil helps recreate that grilled texture without drying out the buns. 🔥
Sauce and Toppings Prep
Make the homemade sauce (1 tbsp mayo + 1 tsp mustard + 1 tsp honey) up to 5 days ahead and store in a small jar. Keep pickle chips in their original container—they stay crispy for weeks. Portion out 1 tbsp sauce and 2 tbsp pickle chips per serving to avoid soggy sandwiches from excess moisture. 🥒
Nutrition facts
Frequently asked questions
Why does the Arby's roast beef sandwich have such a crispy bun?
The secret lies in grilling the buns over medium heat for 2-3 minutes per side until they develop a golden-brown crust. Using a wire rack while cooling prevents sogginess, and toasting them just before assembly keeps that satisfying crunch.
Can I use regular cheddar cheese instead of sharp cheddar?
Sharp cheddar is essential for that signature Arby's flavor—it melts more smoothly and has a tangier taste. Regular cheddar lacks the sharpness and can turn rubbery when melted. If you must substitute, use a 2-year aged cheddar for the closest flavor profile.
How do I prevent the sandwiches from getting soggy?
Toast the buns right before assembling and keep all components separate until serving. Spread a thin layer of mayo on the buns to act as a glue, but avoid overloading with toppings. Assemble sandwiches with cheese between beef slices—this creates a barrier that keeps the buns crispy.
What's the best way to reheat leftover sandwiches?
Wrap leftovers in foil and reheat in a 375°F oven for 5-7 minutes to restore crispiness. For a quicker method, use a skillet with 1 tbsp vegetable oil over medium heat for 1-2 minutes per side. Never microwave—it turns the buns rubbery.
Can I make this sandwich ahead of time?
Prep components ahead: slice beef and grate cheese up to 3 days in advance, and toast buns up to 2 hours ahead. Store everything separately and assemble just before serving. For freezer meals, assemble without cheese and add it fresh when reheating.