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Hands holding chuck roast sandwich with crispy onions.
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5 from 5 votes

Chuck Roast Sandwich with Crispy Onions

Piled high with fall-apart tender beef, melty cheese, crispy onions, and homemade barbecue sauce, my Chuck Roast Sandwich is out of this world! It's perfect for lunches and dinners, but especially good for game day gatherings!
Prep Time15 minutes
Cook Time3 hours
Total Time3 hours 15 minutes
Course: sandwich
Cuisine: American
Servings: 4

Ingredients

For the bbq sauce

  • 1 1/2 cups ketchup
  • 1 3/4 cups distilled white vinegar
  • 3/4 packed cup brown sugar
  • 1/4 cup honey
  • 1 1/2 tablespoons worcestershire sauce
  • salt and pepper to taste

For the steak sandwich

  • 2 1/2 pounds chuck roast cut into 4 large chunks
  • salt and pepper to taste
  • 3 tablespoons olive oil
  • 4 cups low-sodium beef stock
  • 1 large loaf ciabatta or soft Italian bread, soft rolls, and hero rolls
  • 1 large onion sliced
  • 2 tablespoons cornstarch
  • olive oil for frying
  • 1/2 pound sliced American muenster cheese or mozzarella
  • 2 cups arugula

Instructions

For the bbq sauce

  • Add the bbq sauce ingredients to a saucepot and bring to a simmer, stirring frequently to combine. Taste test and season with salt and pepper as required. Remove the sauce from the heat and set aside.

For the steak sandwich and onions

  • Preheat oven to 300°F and set the racks apart to accomodate a large Dutch oven.
  • Liberally season the chuck roast pieces with salt and pepper on all sides.
  • Heat a large Dutch oven with the olive oil to medium heat. Sear the chuck roast pieces on all sides then move them to a plate. Add the beef stock to the pot, bring to a boil, and scrape the bottom of the pot to remove any brown bits. Turn off the heat and mix in 1 cup of the bbq sauce, return the beef to the pot, and cover. Place the pot in the oven and braise until the beef is fork tender and shreddable (about 3 hours).
  • Meanwhile, coat the onions in cornstarch and let sit 10 minutes.
  • Pour olive oil 1" high in a high walled pan or pot and heat to 370°F.
  • Fry the onions until crisp and brown and remove them with a slotted spoon to a paper towel lined baking sheet or wire rack. Fry in multiple batches to not overcrowd the pot. Blot the onions with paper towels and season with a sprinkle of salt.
  • Remove the chuck roast pieces from the pot and place into a bowl. Shred with 2 forks or your hands. Mix in a 1/2 cup of the reserved braising liquid and a 1/2 cup of bbq sauce.
  • Slice the loaf open and place onto a baking sheet. Layer the shredded chuck roast and top with the muenster cheese. Place in the oven for a few minutes to melt the cheese. Top with arugula and then the crispy onions. Spread a layer of bbq sauce onto the top layer of bread and close the sandwich. Slice into 4 sections. Enjoy!

Notes

  • Servings.  Makes 4 large or 6 smaller sandwiches.
  • Bread.  A softer bread works better than a crusty loaf.  A ciabatta loaf or individual rolls, soft rolls or hero/hoagie rolls all work well.
  • Chuck roast.  Cook the chuck roast until it is fall apart tender.  3 hours is a rough estimate, if the roast is still tough, continue to cook it longer until is tender and ready to shred.
  • BBQ sauce.  Use the recipe above or your favorite bottled bbq sauce.
  • Cheese.  American muenster cheese can be subbed with mozzaralle or a mild soft provolone.
  • Leftovers.  Save the extra braised beef for up to 3 days in the fridge to make more sandwiches or use for another purpose.  The crispy onions can be saved in a sealed container for up to 3 days and can be used for more sandwiches or for a topping on salads.  The leftover bbq sauce can be saved in the fridge for up to 2 weeks.

Nutrition

Calories: 1177kcal | Carbohydrates: 92.6g | Protein: 85g | Fat: 51.4g | Saturated Fat: 13.5g | Cholesterol: 227mg | Sodium: 1274mg | Sugar: 45.3g | Calcium: 354mg | Iron: 13mg

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