BBQ Brisket Melts Sandwich

When I first tried making BBQ brisket melts, I was instantly hooked by how the tender, smoky brisket paired perfectly with the rich, melted cheese and crisp onions. It’s a sandwich that feels both comforting and gourmet at the same time. Each bite delivers a delightful contrast—the crunch of toasted sourdough, the juicy brisket, and the tangy BBQ sauce all come together in a mouthwatering experience. This recipe has quickly become one of my favorites for sharing with friends and family, especially when I want to impress without spending hours in the kitchen for every meal.

Why You’ll Love This Recipe

This BBQ brisket melts sandwich is incredibly versatile. Whether you’re hosting a casual weekend lunch or looking for a hearty dinner option, it fits the bill perfectly. You can prepare the brisket ahead of time, and the sandwich assembly is quick and satisfying. Also, this recipe is budget-friendly. While brisket may seem like a splurge, it goes a long way when sliced thin and combined with simple ingredients like onions, cheese, and sourdough bread. Plus, you get all the smoky flavors without needing a professional smoker — just a pellet smoker or any indirect smoking method works well.

Versatile

I love how customizable this recipe is. You can swap out the cheese or adjust the BBQ sauce to your preference. Want it spicier? Add a few jalapeños. Prefer it milder? Go easy on the sauce. This sandwich adapts to what you have on hand, making it perfect for busy days or special occasions alike.

Budget-Friendly

Brisket may sound expensive, but it’s surprisingly affordable when you consider how much it yields. A single brisket can make several sandwiches, feeding a crowd without breaking the bank. Plus, the ingredients are simple and easy to find — no fancy or costly items needed here.

Ingredients

• 1 whole brisket, trimmed of excess fat

• Mustard, enough to coat brisket as binder

• Pepper-forward brisket rub, to generously season

• Hickory pellets, for smoking

• Apple cider vinegar, for brisket wrapping

• Beef tallow, 3–4 tablespoons

• Butcher’s paper, for wrapping

• 2 whole onions, diced

• Avocado oil, 2 tablespoons

• Kosher salt, 1 tablespoon

• Unsalted butter, 2 tablespoons (plus extra for toasting)

• Sourdough bread, as needed

• Fried crispy onions, to taste

• Colby Jack cheese, 2 slices per melt

• Provolone cheese, 2 slices per melt

• Favorite BBQ sauce, to taste

  How to Make BBQ Brisket Melts Sandwich

  Making this BBQ brisket melts sandwich may seem like a long process, but with clear steps, it becomes manageable and even enjoyable. I always remind myself that patience is key—especially when smoking brisket to achieve that tender, melt-in-your-mouth texture.

  Step-by-Step Instructions for Making BBQ Brisket Melts Sandwich

  1. Prepare the Brisket
     First, trim the brisket of any excess fat. This helps it cook evenly and avoids greasy bites. Next, spread a thin but even layer of mustard all over the brisket. This acts as a binder for the rub and adds a subtle tang. Then, generously season the entire brisket with a pepper-forward rub. Make sure to cover every side. Once seasoned, place it in the refrigerator for 1 to 2 hours. This allows the spices to penetrate deeply.

  2. Set Up the Smoker
     Preheat your pellet smoker to 100°C. Add hickory pellets to the smoker box for that classic smoky flavor. Place a water pan under where the brisket will sit. This keeps the environment moist during the long cooking process. Smoke the brisket at this temperature for about 9 to 10 hours. You want the internal temperature to reach 74–77°C at this stage.

  3. Wrap the Brisket
     Once it reaches the target temperature, remove the brisket from the smoker. Wrap it tightly in butcher’s paper. Before sealing, splash a bit of apple cider vinegar and add 3 to 4 tablespoons of beef tallow over the brisket. This helps keep it moist and tender. Return the wrapped brisket to the smoker and increase the temperature to 120°C. Continue smoking until the internal temperature reaches 96–97°C.

  4. Rest the Brisket
     Remove the brisket from the smoker and let it rest while still wrapped. Place it in a cooler or insulated container for 2 to 3 hours. Resting is crucial as it allows the juices to redistribute, ensuring each slice is tender and juicy.

  5. Caramelize the Onions
     While the brisket rests, heat a skillet over medium heat. Add 2 tablespoons of avocado oil and 2 tablespoons of unsalted butter. Once melted, add diced onions and 1 tablespoon of kosher salt. Cook the onions slowly, stirring often, until they turn a deep golden brown and become richly caramelized. This step takes patience but adds incredible sweetness and depth to the sandwich.

  6. Assemble the Sandwich
     Take slices of sourdough bread and spread unsalted butter on one side of each slice. On the unbuttered side, start layering: place a slice of Colby Jack cheese, add sliced brisket, spread some caramelized onions, sprinkle fried crispy onions, drizzle your favorite BBQ sauce, then add a slice of Provolone cheese. Top with another slice of sourdough bread, buttered side up.

  7. Toast the Melt
     Heat a cast iron skillet over medium heat. Add a bit of unsalted butter. Place the assembled sandwich in the skillet and toast for 3 to 4 minutes on each side. Flip carefully once to avoid spilling the fillings. Toast until the bread is golden brown and the cheese is fully melted.

  Quick and Easy Tips

  • Prepare the brisket the day before.

  • Caramelize onions while the meat rests.

  • Use a cast iron skillet for even toasting.

  Customizable Options

  • Swap Colby Jack with Cheddar or Monterey Jack.

  • Add pickled jalapeños for a spicy kick.

  • Use gluten-free sourdough if needed.

  Crowd-Pleasing Potential

  This sandwich is perfect for gatherings. It combines smoky, savory, sweet, and tangy flavors everyone loves. Make a big batch of brisket and watch your guests come back for seconds.

  FAQs About BBQ Brisket Melts Sandwich

  Q: Can I use a regular oven if I don’t have a smoker?
  A: Yes, you can cook the brisket low and slow in the oven. Wrap it tightly in butcher’s paper or foil and bake at 120°C (250°F) for several hours until tender.

  Q: How do I know when the brisket is done?
  A: Use a meat thermometer to check the internal temperature. It’s ready when it reaches 96–97°C (205–207°F), which ensures tenderness.

  Q: Can I prepare the brisket ahead of time?
  A: Absolutely. You can smoke the brisket a day before, then refrigerate it wrapped. Reheat gently before assembling the sandwich.

  Q: What if I want a vegetarian version?
  A: Try substituting the brisket with smoked mushrooms or jackfruit and follow the rest of the recipe similarly.

  Q: Can I use a different type of bread?
  A: Yes, but sourdough’s tang and texture complement the flavors best. You can try rye or ciabatta for variety.

  Q: How long do the caramelized onions take?
  A: About 20–30 minutes over medium heat. Stir frequently to avoid burning and to develop deep color and flavor.

  Q: Can I freeze leftovers?
  A: Yes, slice the brisket and freeze it in airtight containers. Reheat gently in the oven or microwave.

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  BBQ Brisket Melts Sandwich

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  This BBQ brisket melts sandwich combines tender smoked brisket with melted cheese, caramelized onions, and crispy fried onions on toasted sourdough. It’s smoky, tangy, and perfect for any casual meal or gathering.

  • Total Time: 10 hours 30 minutes (30 minutes prep + 10 hours cooking)
  • Yield: 4 sandwiches (4 melts) 1x

  Ingredients

  Scale 1x2x3x

  • 1 whole brisket, trimmed of excess fat

  • Mustard, enough to coat brisket as binder

  • Pepper-forward brisket rub, to generously season

  • Hickory pellets, for smoking

  • Apple cider vinegar, for brisket wrapping

  • Beef tallow, 3–4 tablespoons

  • Butcher’s paper, for wrapping

  • 2 whole onions, diced

  • Avocado oil, 2 tablespoons

  • Kosher salt, 1 tablespoon

  • Unsalted butter, 2 tablespoons (plus extra for toasting)

  • Sourdough bread, as needed

  • Fried crispy onions, to taste

  • Colby Jack cheese, 2 slices per melt

  • Provolone cheese, 2 slices per melt

  • Favorite BBQ sauce, to taste

  Cook Mode Prevent your screen from going dark

  Instructions

  • Trim brisket of excess fat. Coat evenly with mustard as a binder.

  • Apply pepper-forward rub generously on all sides. Refrigerate 1–2 hours.

  • Preheat pellet smoker to 100°C. Add hickory pellets and place water pan under meat. Smoke brisket 9–10 hours until internal temperature reaches 74–77°C.

  • Remove brisket, wrap tightly in butcher’s paper with apple cider vinegar splash and 3–4 tbsp beef tallow. Return to smoker at 120°C until internal temperature reaches 96–97°C.

  • Rest brisket wrapped in cooler for 2–3 hours.

  • In skillet, sauté diced onions with avocado oil, 2 tbsp unsalted butter, and kosher salt over medium heat. Stir often until deeply caramelized.

  • Butter sourdough bread slices on one side. On unbuttered side, layer Colby Jack cheese, sliced brisket, caramelized onions, fried crispy onions, BBQ sauce, Provolone cheese, and top with another bread slice, buttered side up.

  • Toast sandwiches in a cast iron skillet over medium heat, 3–4 minutes per side, until golden brown and cheese melts.

  Notes

  • Use a meat thermometer for accurate temperature.

  • Resting the brisket ensures juicy slices.

  • Adjust BBQ sauce to taste.

  • Substitute cheeses or bread as preferred.

  • Author: Mohamed
  • Prep Time: 30 minutes
  • Cook Time: 600 minutes (10 hours smoking + resting)