Description
This BBQ Brisket Melts recipe features tender, smoky smoked brisket layered with two types of melting cheese, crispy fried onions, and barbecue sauce sandwiched between toasted sourdough bread. The brisket is slow-smoked over hickory wood pellets, wrapped and finished with added moisture for optimum juiciness, then sliced and assembled into delicious melts grilled golden brown in a cast iron skillet. Perfect for satisfying barbecue lovers craving a cheesy, flavorful sandwich with robust smoky notes.
Ingredients
Scale
Brisket and Seasoning
- 1 whole brisket (around 8–10 pounds)
- Mustard, enough to lightly coat the brisket for binding
- Pepper-forward brisket rub, generous amount for seasoning
- Hickory wood pellets, for smoking
- Apple cider vinegar, 1/4 cup (for wrapping)
- Beef tallow, 2 tablespoons (for wrapping)
Sandwich Ingredients
- Sourdough bread, slices as needed
- Colby jack cheese, sliced or shredded, about 4-6 ounces
- Provolone cheese, sliced, about 4-6 ounces
- Fried crispy onions, 1 cup
- BBQ sauce, 1/2 cup
- Unsalted butter, 2 tablespoons (for grilling sandwiches)
- Avocado oil, 1 tablespoon (for caramelizing onions)
- Diced onions, 1 medium onion (for caramelization)
Instructions
- Prepare the Brisket: Trim excess fat from the brisket, leaving a thin layer for flavor. Lightly coat the brisket with mustard as a binding agent to help the rub stick evenly. Generously season the brisket with a pepper-forward rub, making sure every side is well covered. Refrigerate it for 1-2 hours to allow the rub to infuse.
- First Smoke: Preheat your pellet smoker to 210°F and fill it with hickory wood pellets. Place the brisket in the smoker and cook low and slow for 9-10 hours until the internal temperature reaches between 165-170°F, imparting a deep smoky flavor.
- Wrap and Finish Smoking: Remove the brisket from the smoker. Wrap it tightly in butcher paper along with 1/4 cup of apple cider vinegar and 2 tablespoons of beef tallow to maintain moisture and enhance flavor. Increase the smoker temperature to 250°F and return the wrapped brisket to the smoker. Continue cooking until the internal temperature reaches 204-206°F.
- Rest the Brisket: Once done, remove the brisket from the smoker and let it rest for 2-3 hours. This step allows the juices to redistribute, making the meat tender and juicy.
- Caramelize the Onions: While the brisket rests, heat avocado oil and butter in a pan over medium heat. Add diced onions and cook slowly until they are deeply caramelized and sweet, about 15-20 minutes. Stir occasionally to prevent burning.
- Assemble the Melts: Slice the rested brisket thinly. On a slice of toasted sourdough bread, layer fried crispy onions, a generous amount of sliced brisket, Colby jack cheese, provolone cheese, and a drizzle of BBQ sauce. Top with another slice of toasted sourdough.
- Grill the Sandwiches: Heat a cast iron skillet over medium heat and melt unsalted butter. Place the assembled sandwiches in the skillet and cook until the bread turns golden brown and crispy, and the cheese melts thoroughly, approximately 3-4 minutes per side.
- Serve: Remove the sandwiches from the skillet, slice in half if desired, and serve immediately while hot and melty.
Notes
- Using butcher paper instead of foil during wrapping allows the brisket to continue breathing and develop a better bark while retaining moisture.
- Make sure to monitor smoker temperatures consistently for even cooking.
- You can substitute Colby jack and provolone with other mild melting cheeses if preferred.
- Allowing the brisket to rest is crucial for juicy slices that don’t dry out the sandwich.
- For extra smoky flavor, consider adding a smoke tube or additional wood chips in the smoker.
- Use unsalted butter when grilling sandwiches to control sodium levels.
Keywords: BBQ Brisket, Smoked Brisket Sandwich, Cheese Melt Sandwich, BBQ Melt, Hickory Smoked Brisket, Comfort Food, Grilled Sandwich