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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
  • 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

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)