Copycat Arby’s Smokehouse Brisket Sandwich

This copycat Arby’s Smokehouse Brisket sandwich piles tender, smoky beef brisket onto a toasted bakery-style bun with smoked Gouda, sweet barbecue sauce, creamy mayonnaise, and crispy fried onions.

Make the brisket quickly in a pressure cooker or cook it low and slow for an easy restaurant-inspired dinner, game-day meal, or hearty weekend sandwich.

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Copycat Arby’s Smokehouse Brisket Sandwich Recipe

The Arby’s Smokehouse Brisket sandwich became a fast-food favorite because every layer brought something different to the bite. The brisket provided rich beef flavor, smoked Gouda added creaminess, barbecue sauce supplied sweetness and tang, mayonnaise balanced the smoky flavors, and fried onions added the crunch.

This homemade copycat version recreates those same contrasts without requiring a traditional smoker. Hickory liquid smoke, smoked paprika, Worcestershire sauce, and barbecue sauce give the brisket a smokehouse-inspired flavor, while pressure cooking or slow cooking makes the meat tender.

It is a helpful recipe for anyone craving the discontinued or difficult-to-find sandwich, and it lets you control the sauce, seasoning, cheese, and toppings.

For the closest copycat result, use sliced smoked Gouda rather than cheddar cheese sauce. Cheddar sauce would still taste delicious, but it would make the sandwich more like a brisket version of a Beef ’n Cheddar.

Why You’ll Love This Recipe

No smoker is required. Liquid smoke, smoked paprika, Worcestershire sauce, and barbecue sauce create smokehouse-style flavor using ordinary kitchen equipment.

You can choose the cooking method. Prepare the brisket in a pressure cooker when you need it sooner or use the slow cooker for a relaxed, hands-off meal.

The textures work together. Tender brisket, melted cheese, creamy sauce, crunchy onions, and a toasted bun make every bite satisfying.

It can be prepared ahead. Cook and refrigerate the brisket in advance, then slice and reheat it before assembling the sandwiches.

The leftovers are versatile. Extra brisket can be used in tacos, nachos, quesadillas, baked potatoes, grilled cheese, or another round of sandwiches.

Ingredients for Copycat Arby’s Smokehouse Brisket

This recipe makes approximately six generously filled sandwiches.

For the Smoky Brisket

3 pounds beef brisket, trimmed of thick, hard exterior fat
1 teaspoon garlic powder
1 teaspoon onion powder
1 teaspoon smoked paprika
1/2 teaspoon celery salt
1/2 teaspoon seasoned salt
1/2 teaspoon freshly ground black pepper
1 cup beef broth or water
2 tablespoons Worcestershire sauce
1 tablespoon hickory liquid smoke
1 cup thick sweet-smoky barbecue sauce, divided

For the Sandwiches

6 bakery-style sandwich rolls, brioche buns, or sturdy hamburger buns
6 to 12 slices smoked Gouda cheese
1/2 cup mayonnaise, or as needed
2 cups crispy fried onions

Ingredient Notes

Beef brisket: Trim away thick, hard pieces of exterior fat, but leave a thin layer of softer fat to help keep the meat moist while it cooks.

Liquid smoke: Hickory liquid smoke creates smokehouse flavor without a smoker. Measure it carefully because it is concentrated and can become overpowering.

Barbecue sauce: Choose a thick, sweet-smoky barbecue sauce. Use half in the cooking liquid and reserve the remaining half for the sandwiches. For a tangier variation, try my Carolina BBQ sauce.

Smoked Gouda: Thinly sliced smoked Gouda softens quickly over the hot meat and recreates the signature smoky, creamy layer.

Mayonnaise: A thin coating balances the barbecue sauce and adds moisture without covering up the brisket.

Crispy fried onions: Add them immediately before serving so they retain their crunch.

How to Make a Copycat Arby’s Smokehouse Brisket Sandwich

1. Prepare the brisket

Pat the brisket dry with paper towels.

Trim away any very thick or hard pieces of exterior fat. Leave a thin layer of softer fat to help flavor the meat and keep it moist.

2. Season the brisket

In a small bowl, combine the garlic powder, onion powder, smoked paprika, celery salt, seasoned salt, and black pepper.

Rub the seasoning mixture evenly over the top, bottom, and sides of the brisket.

3. Prepare the pressure cooker

Pour the beef broth, Worcestershire sauce, liquid smoke, and 1/2 cup of the barbecue sauce into the inner pot of a 6-quart pressure cooker.

Stir gently to combine.

4. Pressure cook the brisket

Place the seasoned brisket into the pressure cooker.

Secure the lid and make sure the pressure-release valve is set to Sealing.

Cook on High Pressure for 50 minutes.

5. Release the pressure

When the cooking time ends, allow the pressure to release naturally for 15 to 20 minutes.

Carefully move the valve to Venting to release any remaining pressure according to the pressure cooker manufacturer’s instructions.

6. Check the brisket for tenderness

Open the lid and insert a fork into the thickest part of the brisket. The fork should slide into the meat easily.

If the brisket is still firm or difficult to pierce, secure the lid and cook on High Pressure for another 10 minutes. Allow the pressure to release naturally for 10 minutes before checking it again.

7. Rest the brisket

Transfer the cooked brisket to a cutting board.

Let it rest for 15 minutes before slicing. This allows the juices to redistribute through the meat.

8. Slice against the grain

Look for the direction of the long muscle fibers and cut across them.

Slice the brisket thinly for the closest restaurant-style texture.

If the meat is too tender to slice cleanly, pull it into large pieces rather than finely shredding it.

9. Warm the barbecue sauce

Place the remaining 1/2 cup barbecue sauce in a small saucepan.

Warm it over low heat, stirring occasionally, until heated through.

10. Toast the buns

Split the sandwich rolls.

Place the rolls cut-side down in a dry skillet over medium heat for 1 to 2 minutes, or until lightly toasted.

You can also place the buns cut-side up under the broiler for approximately 1 minute. Watch them closely so they do not burn.

11. Assemble the sandwiches

Spread approximately 1 tablespoon mayonnaise over the cut side of each bottom bun.

Add a generous portion of hot sliced brisket.

Place one or two slices of smoked Gouda directly over the hot meat so the cheese begins to soften.

Drizzle approximately 1 to 2 tablespoons of warm barbecue sauce over each sandwich.

Top each sandwich with approximately 1/3 cup crispy fried onions.

Add the toasted top bun and serve immediately.

Slow Cooker Directions

Prepare and season the brisket as directed.

Pour the beef broth, Worcestershire sauce, liquid smoke, and 1/2 cup barbecue sauce into a 6-quart slow cooker.

Place the seasoned brisket into the slow cooker and turn it gently to coat it in the cooking liquid.

Cover and cook on LOW for 8 to 10 hours, or until a fork slides easily into the thickest part of the brisket.

Transfer the brisket to a cutting board and let it rest for 15 minutes.

Slice the meat thinly against the grain.

Warm the remaining barbecue sauce, toast the buns, and assemble the sandwiches with mayonnaise, brisket, smoked Gouda, barbecue sauce, and crispy fried onions.

The Best Order for Layering the Sandwich

Build each Smokehouse Brisket sandwich in this order:

Toasted bottom bun
Mayonnaise
Hot sliced brisket
Smoked Gouda
Warm barbecue sauce
Crispy fried onions
Toasted top bun

Placing the smoked Gouda directly over the hot brisket helps the cheese soften. Adding the onions last keeps them away from the warm sauce until serving time.

Tips for Tender Smokehouse Brisket

Do not add extra liquid smoke. Liquid smoke is concentrated. Too much can make the brisket taste harsh, bitter, or artificial.

Let the brisket rest. Resting helps the meat retain its juices and makes it easier to slice.

Slice against the grain. Cutting across the long muscle fibers creates a more tender bite.

Save some of the cooking liquid. A few spoonfuls will help keep the sliced brisket moist during storage and reheating.

Warm the barbecue sauce. Cold sauce can cool the meat and keep the Gouda from softening.

Toast the rolls. Toasted bread holds up better against the juicy brisket, mayonnaise, and barbecue sauce.

Add the onions last. Steam and sauce will soften crispy fried onions quickly.

Troubleshooting

Why is my brisket still tough?

Brisket becomes tender when its connective tissue has enough time to break down. If it is still tough after 50 minutes, return it to the pressure cooker with its liquid and cook it for another 10 minutes.

Why is my brisket dry?

Dry brisket may have been overcooked, sliced too soon, reheated over high heat, or stored without cooking liquid. Keep the sliced meat with a small amount of broth or reserved juices.

Why does the liquid smoke taste too strong?

Liquid smoke is highly concentrated. Measure it rather than pouring it directly from the bottle. Extra beef broth or barbecue sauce may help soften an overly smoky flavor.

Why is my sandwich soggy?

Toast both cut sides of the bun, allow excessive liquid to drain from the brisket, and assemble the sandwich immediately before serving.

Variations and Substitutions

Use leftover brisket: Skip the cooking steps and reheat leftover brisket gently with a splash of beef broth or cooking juices.

Use regular Gouda: Regular Gouda is the closest mild substitute when smoked Gouda is unavailable.

Try smoked provolone: Smoked provolone has a sharper flavor but still pairs well with brisket.

Add Horsey Sauce: Replace some or all of the mayonnaise with creamy horseradish sauce.

Make it extra smoky: Choose smoked Gouda and a smoky barbecue sauce rather than increasing the liquid smoke.

Make brisket sliders: Use small slider rolls and smaller portions of meat for game day, parties, or casual gatherings.

Optional Homemade Arby’s Sauce

Arby’s Sauce was not the defining sauce on the original Smokehouse Brisket sandwich, but it makes a flavorful dipping sauce for the sandwich or fries.

Arby’s Sauce Ingredients

1/2 cup ketchup
2 tablespoons water
1 tablespoon brown sugar
1 tablespoon apple cider vinegar
1 teaspoon Worcestershire sauce
1/2 teaspoon garlic powder
1/2 teaspoon onion powder
Salt and black pepper to taste

How to Make Homemade Arby’s Sauce

Combine the ketchup, water, brown sugar, apple cider vinegar, Worcestershire sauce, garlic powder, onion powder, salt, and pepper in a small saucepan.

Whisk over low heat for 5 to 7 minutes, stirring frequently, until the sauce is smooth and slightly thickened.

Let it cool for several minutes and serve it on the side rather than replacing the barbecue sauce on the sandwich.

Make-Ahead Tips

The brisket can be cooked up to three days before serving.

Refrigerate it with some of its cooking liquid. Chilled brisket is often easier to slice neatly than freshly cooked brisket.

Reheat the slices gently in a covered skillet with a small amount of broth, barbecue sauce, or reserved cooking liquid.

Toast the buns and add the cheese, sauces, and crispy onions only when you are ready to serve.

Storage and Reheating

Store the brisket separately from the buns, cheese, sauces, and crispy onions.

Place cooled brisket in an airtight container with a small amount of cooking liquid and refrigerate it for up to four days.

Reheat the brisket in a covered skillet over low heat with a splash of beef broth or reserved cooking liquid.

Individual portions can also be warmed in the microwave at reduced power in short intervals.

Do not refrigerate fully assembled sandwiches. The buns will become soggy, and the fried onions will lose their crunch.

Can You Freeze Cooked Brisket?

Yes. Allow the brisket to cool completely.

Package it with a small amount of cooking liquid in a freezer-safe container or freezer bag.

Freeze for up to three months.

Thaw the brisket overnight in the refrigerator and reheat it gently before assembling the sandwiches.

Frequently Asked Questions

What is on an Arby’s Smokehouse Brisket sandwich?

The smokehouse-style sandwich is made with sliced brisket, smoked Gouda, barbecue sauce, mayonnaise, and crispy fried onions on a toasted bakery-style bun.

What cheese is used on an Arby’s Smokehouse Brisket sandwich?

Smoked Gouda is the best choice for recreating the sandwich’s creamy texture and smoky flavor.

Can I use cheddar cheese sauce?

Yes, but cheddar sauce will make the sandwich taste more like a brisket version of a Beef ’n Cheddar. Smoked Gouda creates a closer copycat result.

Can I make this brisket without a pressure cooker?

Yes. Cook it in a slow cooker on LOW for 8 to 10 hours, or until it is fork-tender.

Can I use leftover brisket?

Yes. Warm leftover brisket gently with a splash of beef broth, cooking juices, or barbecue sauce, then assemble the sandwich as directed.

Can I leave off the mayonnaise?

Yes. Leave it off or replace it with Horsey Sauce, garlic mayonnaise, ranch dressing, or additional barbecue sauce.

What can I substitute for smoked Gouda?

Regular Gouda is the closest substitute. Smoked provolone, Havarti, Monterey Jack, or mild cheddar can also be used.

How do I keep the crispy fried onions crunchy?

Add them immediately before serving and avoid placing them directly against the sauce until the sandwich is assembled.

Mrs. Wolowitz Would Understand

Howard Wolowitz may have believed his mother was the only true brisket expert, and Mrs. Wolowitz certainly never lacked confidence in her cooking.

She usually served her brisket on a plate—unless it was Thanksgiving and she was making Tur-brisk-fil, her memorable turkey stuffed with brisket stuffed with gefilte fish.

This sandwich gives brisket an entirely different life. Instead of becoming a traditional dinner, it turns into a towering stack of smoky beef, creamy cheese, tangy sauce, and crunchy onions tucked inside a warm bun.

It is the kind of sandwich that feels indulgent enough for game day but familiar enough for a cozy family dinner.

Final Thoughts

This copycat Arby’s Smokehouse Brisket sandwich is smoky, cheesy, saucy, crunchy, and wonderfully messy in all the right ways.

The pressure cooker makes it possible to create tender brisket without spending all day tending a smoker, while smoked Gouda, barbecue sauce, mayonnaise, and crispy fried onions recreate the layers that made the restaurant sandwich memorable.

Make it for a weekend dinner, game day, or any evening when an ordinary hamburger simply will not do.

For more nostalgic family favorites, open the recipe box and visit Grandma’s Recipes and Vintage Favorites.

This independently developed copycat recipe is inspired by a restaurant menu item. Mommy’s Memorandum is not affiliated with or endorsed by Arby’s.

Close the recipe box gently—there’s another family favorite waiting inside.