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We have the meats! This homemade Smoked Beef and Cheddar sandwich is so easy and tasty, you will never go back to the fast food version. The meaty cheesy goodness makes for a tasty treat you will want for lunch, dinner or both!

Be sure to check out my Easy Grilled Spicy Chicken Sandwich for a tasty alternative.

smoked beef and cheddar sandwich on a plate.

Step 1: Where’s the beef?

First things first, you have to get the meat on the grill.  For this recipe, I went with a beef eye of round. It’s lean and perfect for this application. If you can’t find an eye of round, any lean beef cut will work here.

beef eye of round seasoned with rub.

Coat the beef with dijon mustard as the binder and season with your choice of beef seasoning. I went with Rolling bones barbecue beef seasoning which gives strong pepper, onion and garlic flavors. Andy beef seasoning here will work and you can also just use salt and pepper.

seasoned beef on the grill.

Preheat the grill to 250 degrees and set it for indirect heat.  We’ll be smoking this guy low and slow. I also added a few wood chunks to my charcoal for some extra smoke, but that’s not required. Smoke the beef roast for about 2 hours or until the internal temperature reaches 120 degrees.  Remove it from the grill and wrap it very tightly in aluminum foil.

This will stop the cooking process, allow the juices to redistribute and make for a much better final product. At this point, you can also pop this in the fridge and use it for cold cuts. I promise this version will beat anything you can get at the store!

If you like beefy and meaty sandwiches, you must try my Smoked and Shredded Italian Beef Sandwich.

smoked beef wrapped in aluminum foil.

Dad’s Seasonings

Must have grillin seasonings!

Step 2: Let’s get saucy.

This recipe requires 2 special sauces that complete this amazing copycat Arby’s sandwich.

First, the horsey sauce adds a layer of spice and sweetness that is the base of the sandwich.  In a mixing bowl, add white vinegar, sugar, mayo and ground horseradish.  Mix the ingredients together and set aside.

Second, we have our cheese sauce. The gooey cheese sauce is the perfect topping for this smoked beef and cheddar sandwich. Start by melting your butter in a cast iron skillet. Add the flour and whisk for a minute or so to cook out the raw flour taste and smell. Next, add milk, whisk again and add chunks of velveeta cheese. Yes it’s fake cheese, but adding velveeta to your cheese sauce will give it a silky smooth consistency. When the velveeta is melted, add the freshly shredded cheddar and continue mixing until melted. It’s important to do this over low heat so the sauce doesn’t break. I did this on the grill but you can do it on the stop as well.

Recipe Tip

Don’t want to make your own sauce? Use store bought nacho cheese sauce instead. Warm it up first and pour it on the sandwich.

cast iron skillet on the grill with cheese sauce.

Step 3: Assemble the Smoked Beef and Cheddar sandwich.

Now we can finally assemble our beef and cheddar sandwiches. I always say that a sandwich is only as good as the bread or bun that it’s served on. And this sandwich needs a hearty bun! I used a savory onion bun

Spread the horsey sauce as the base, slice the smoked beef and add layers on the bun.  Drizzle the gooey cheese over the top and cover with the onion bun.  Biting into this sandwich will deliver on those herby onion flavors from the bun, the cheesy goodness from the sauce, the amazing smokey beefiness from the meat and finally you get hit with the sweet horseradish sauce.  This is the ultimate must have smoked beef and cheddar sandwich! Enjoy!

beef and cheddar sandwich on a plate.
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Frequently Asked Questions:

Can I make this in the oven or stove top?

Absolutely! Start by roasting the beef low and slow in the oven, just like i did on the smoker, and then follow the rest of the recipe as listed.

How can I prevent my cheese sauce from braking?

The most common reason for braking a cheese sauce is cooking it over too high heat. Turn down the heat, melt the cheese slowly and it will come out perfect!

Similar Sandwich Ideas:

If you tried this Smoked Beef and Cheddar or any other recipe on my blog, please leave a 🌟 star rating and let me know how it went in the📝 comments. I love hearing from you!

5 from 1 vote

Smoked Beef and Cheddar

We have the meats! This homemade smoked beef and cheddar sandwich is so easy and tasty, you will never go back to the fast food version.
Prep Time: 15 minutes
Cook Time: 2 hours
Servings: 6 People

Ingredients 

Beef Ingredients

  • 3 lbs Beef eye of round
  • 3 tbsp Steak seasoning
  • 1 tbsp Dijon mustard
  • 4 Onion buns

Horsey Sauce Ingredients

  • 1/2 tbsp White vinegar
  • 2 tsp Sugar
  • 2 tbsp Ground horseradish
  • 1 cup Mayo

Cheese Sauce Ingredients

  • 1 cup Milk
  • 1 cup Shredded cheddar cheese
  • 1/2 cup Velveeta
  • 1 tbsp Butter
  • 1 tbsp All purpose flour

Instructions 

  • Coat the beef eye of round with dijon mustard and season on all sides with the beef seasoning
  • Preheat your grill to 250 degrees and set up for indirect heat. Add a few chunks of wood for addtional smoke flavor.  Smoke the beef roast for about 2 hours or until the internal temperature reaches 120 degrees.  Wrap it in foil and let if rest for 45 minutes to 1 hour.
  • While the beef roast is resting, we can start on the cheese sauce. Melt the butter in a cast iron skillet, over medium direct heat. Add the flour and whisk for a minute or 2 to cook out the raw flour taste and smell.
  • Add the milk, velveeta cheese and continue mixing until the cheese is melted.
  • Add the shredded cheddar cheese, mix and cook until the sauce is silky smooth. Remove from the heat.
  • For the horsey sauce, in a mixing bowl, add white vinegar, sugar, mayo and horseradish.  Mix the ingredients together and set aside.
  • Remove the beef roast from the foil wrap and slice as thinly as you can.
  • Assemble the sandwich on an onion roll, add the horsey sauce, sliced beef, cheese sauce, and enjoy!

Nutrition

Calories: 1129kcal | Carbohydrates: 29g | Protein: 56g | Fat: 87g | Saturated Fat: 29g | Polyunsaturated Fat: 19g | Monounsaturated Fat: 28g | Trans Fat: 3g | Cholesterol: 217mg | Sodium: 1392mg | Potassium: 903mg | Fiber: 1g | Sugar: 12g | Vitamin A: 723IU | Vitamin C: 4mg | Calcium: 523mg | Iron: 6mg
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About Maciek

I make easy meals that anyone can replicate at home. I’m not a professionally trained chef, just your average guy that likes to fire up the grill. So follow along and see what’s cooking today!

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