Smoked Brisket Cheese Sandwiches

This BBQ brisket melt sandwich transforms leftover smoked brisket into something magical. The combination of tender, smoky meat with melty cheese and sweet caramelized onions creates a sandwich that's far more than the sum of its parts. I've been making these for years as my secret weapon for using up brisket after weekend barbecues.

I first developed this recipe after a family barbecue when we had brisket leftovers but wanted something different than just reheated meat. Now my family actually gets excited when we have brisket leftovers because they know these melts will follow!

Ingredients

• Brisket: fresh or leftover adds the smoky foundation of the sandwich
• Mustard: as a binder helps seasoning adhere to the meat for smoking
• Favorite brisket rub: preferably pepper forward builds layers of flavor
• Hickory pellets: for smoking provide that authentic BBQ flavor
• Apple cider vinegar: adds moisture and brightness during the wrap stage
• Beef tallow: 3–4 tablespoons creates incredible richness and moisture
• Whole onions: become sweet and jammy when caramelized
• Avocado oil: high smoke point perfect for caramelizing onions
• Kosher salt: enhances all the flavors especially in the onions
• Unsalted butter: adds richness to onions and creates perfectly toasted bread
• Sourdough bread: sturdy enough to hold all ingredients with great flavor
• Fried crispy onions: add textural contrast and more onion flavor
• Colby jack cheese: melts beautifully with mild flavor that complements brisket
• Provolone cheese: adds a slightly sharper note and excellent meltability
• Favorite BBQ sauce: ties everything together with sweetness and tang

Step-by-Step Instructions

Prepare the Brisket:

Trim excess fat from brisket leaving about 1/4 inch fat cap to render during cooking. Apply mustard evenly across all surfaces which acts as a binder for your rub. The mustard flavor completely disappears during cooking but helps create a beautiful bark.

Season and Rest:

Season generously with your favorite pepper forward brisket rub coating all sides evenly. Place in refrigerator for 1–2 hours which allows the rub to adhere and penetrate slightly. This rest time is critical for flavor development.

Smoke the Brisket:

Preheat smoker to 210 degrees using hickory pellets which provide classic BBQ flavor. Place a water pan underneath the brisket to maintain humidity in the cooking chamber. Smoke for 9–10 hours until internal temperature reaches 165–170 degrees. Be patient during this phase as the meat absorbs maximum smoke flavor.

The Texas Crutch:

Once internal temperature reaches 165–170 degrees wrap brisket tightly in butchers paper and add a splash of apple cider vinegar and 3–4 tablespoons of beef tallow. This combination creates incredible moisture and richness. Increase smoker temperature to 250 degrees and continue cooking until internal temperature reaches 204–206 degrees.

Proper Rest:

Allow wrapped brisket to rest in a cooler for 2–3 hours. This resting phase is absolutely critical as the meat reabsorbs juices and the texture becomes perfect. The cooler maintains temperature while preventing overcooking.

Caramelize Onions:

Dice onions and sauté with avocado oil, kosher salt, and butter over medium low heat for 30–40 minutes stirring occasionally until deep golden brown and incredibly sweet. The slow cooking process converts the onions sugars creating rich caramelized flavor.

Sandwich Assembly:

Begin with sourdough bread slice and layer fried crispy onions, Colby jack cheese, thick slices of brisket, caramelized onions, a drizzle of BBQ sauce, provolone cheese, and top with second bread slice. The specific layering ensures proper melting and flavor distribution.

Final Toast:

Add butter to cast iron skillet over medium heat and toast sandwich for 3–4 minutes per side pressing gently with spatula. The cast iron provides even heat creating perfectly crispy golden bread while melting the cheese completely.

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My favorite part of this recipe is watching peoples faces when they take their first bite. The combination of textures from the crispy bread to the tender brisket creates an experience beyond a simple sandwich. Even my father in law who rarely offers cooking compliments requested this specifically after trying it the first time.

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Brisket Selection and Preparation

When selecting brisket for this recipe look for Choice grade or higher with good marbling throughout. A whole packer brisket includes both the point and flat sections with the point being fattier and more flavorful while the flat is leaner. For sandwiches I prefer using the point section if separating the cuts but a properly smoked whole brisket provides excellent variety in each bite. The trimming process is important leaving just enough fat to render during cooking without becoming excessive. Remember that brisket will shrink considerably during smoking so purchase accordingly about 1/2 pound raw weight per sandwich.

Making Ahead and Storage

These melts are actually perfect for meal prep. You can smoke the brisket up to three days in advance keeping it wrapped tightly in the refrigerator. When ready to use simply slice the cold brisket thinly against the grain which is much easier than slicing warm meat. The caramelized onions can also be prepared up to three days ahead and refrigerated in an airtight container. For the complete sandwiches assemble them without the final toasting step wrap individually in foil and refrigerate for up to two days. When ready to eat simply unwrap and toast in a buttered skillet until golden and heated through.

Variations and Substitutions

While this recipe specifies sourdough bread feel free to substitute with Texas toast brioche or even a hearty ciabatta based on your preference. The cheese selections are also flexible try pepper jack for extra heat smoked gouda for additional smokiness or even a blue cheese for stronger flavor. Vegetarians can substitute portobello mushrooms marinated in a smoky sauce and grilled until tender. For those without smokers you can achieve good results by slow cooking brisket in the oven with liquid smoke though the authentic smoky flavor will be somewhat reduced. Gluten free breads work well but choose sturdy varieties that will hold up to the substantial fillings.

Serving Suggestions

These brisket melts shine as the centerpiece of a meal but benefit from thoughtful sides. Classic options include homemade potato chips coleslaw or a simple green salad with vinaigrette to cut through the richness. For special occasions serve alongside smoked baked beans corn on the cob or garlic parmesan fries. A pickle spear provides welcome acidity that balances the rich sandwich. For beverages consider an ice cold craft beer amber ale or bourbon works particularly well with the smoky flavors or a simple sweet tea for non alcoholic options. When serving for gatherings consider cutting sandwiches into quarters for easier handling.

Frequently Asked Questions About the Recipe

→ What kind of brisket is best for these melts?

A whole packer brisket (containing both point and flat) works best as it provides good marbling and flavor. However, you can use just the point section for extra tenderness and fat content. Either way, ensure you trim excess fat and season well with a pepper-forward rub.

→ Can I use pre-cooked brisket from a restaurant?

Absolutely! While the recipe details smoking your own brisket for ultimate flavor control, quality restaurant brisket works wonderfully. Simply warm the slices before building your sandwich, and continue with the caramelized onions and assembly instructions.

→ What can I substitute for sourdough bread?

Texas toast, brioche, or ciabatta make excellent alternatives. The key is choosing a sturdy bread that can hold up to the hearty fillings while toasting well. Whatever bread you choose, buttering the outside ensures a golden, crispy exterior.

→ How do I store and reheat leftover brisket for future melts?

Store leftover brisket with its juices in an airtight container for up to 4 days in the refrigerator. For longer storage, freeze portions with some juice in vacuum-sealed bags. To reheat, warm gently in a covered pan with a splash of beef broth, or sous vide at 165°F if available.

→ What sides pair well with these brisket melts?

Classic pairings include coleslaw, potato salad, baked beans, or crispy french fries. For a lighter option, a simple green salad with vinaigrette offers a refreshing contrast to the rich sandwich. Pickles or pickled vegetables also provide a nice acidic balance to the smoky, savory flavors.

→ Can I make these melts without a smoker?

Yes! You can prepare brisket in a slow cooker or Dutch oven with liquid smoke added for smoky flavor. Cook on low for 8-10 hours until tender. Alternatively, some grocery stores and barbecue restaurants sell smoked brisket that works perfectly for these sandwiches.