If you’re craving a sandwich that combines smoky, tender brisket, melted cheese, and golden-toasted sourdough bread, this BBQ Brisket Melt is the answer. Perfectly balanced with sweet caramelized onions, crispy fried onions, and your favorite BBQ sauce, it’s a hearty and satisfying dish that’ll steal the show at any meal.

This guide takes you through every step—from preparing the brisket to assembling the melt. Get ready to treat yourself to this ultimate comfort food!

Why This Recipe Works

  • Smoky Brisket: Cooking brisket low and slow on a pellet smoker infuses it with deep, rich flavor.
  • Layered Flavors: The combination of caramelized onions, BBQ sauce, and two cheeses creates a melt-in-your-mouth experience.
  • Perfectly Toasted: Golden, buttery sourdough bread seals the deal on this decadent sandwich.

Ingredients

For the Brisket

  • Brisket
  • Mustard (as a binder)
  • Favorite brisket rub (pepper-forward recommended)
  • Hickory pellets (for smoking)
  • Apple cider vinegar
  • Beef tallow (3-4 tablespoons)

For the Onions

  • 2 whole onions
  • 2 tbsp avocado oil
  • 1 tbsp kosher salt
  • 2 tbsp unsalted butter

For the Sandwich

  • Sourdough bread
  • Fried crispy onions
  • 2 slices Colby Jack cheese
  • 2 slices Provolone cheese
  • Favorite BBQ sauce
  • Unsalted butter (for toasting)

How to Make BBQ Brisket Melts

1. Prepare the Brisket

  1. Trim: Remove excess fat from the brisket to allow even cooking and better bark formation.
  2. Season: Spread mustard as a binder, then generously coat the brisket with a pepper-forward rub. Let it sit in the refrigerator for 1-2 hours.
  3. Smoke: Place the brisket on the top shelf of a pellet smoker preheated to 210°F with a water pan underneath. Smoke overnight for 9-10 hours, or until the internal temperature reaches 165-170°F.

2. Wrap and Finish Smoking

  1. Wrap: Remove the brisket and wrap it tightly in butcher’s paper. Spritz with apple cider vinegar and spread 3-4 tablespoons of beef tallow over the brisket before wrapping.
  2. Smoke Again: Increase the smoker temperature to 250°F. Smoke the wrapped brisket until the internal temperature reaches 204-206°F and it’s probe tender.
  3. Rest: Let the wrapped brisket rest in a cooler for 2-3 hours to redistribute juices and lock in flavor.

3. Caramelize the Onions

  1. Dice two onions and sauté them in a skillet with avocado oil, butter, and kosher salt over medium heat.
  2. Cook until golden brown and soft, stirring occasionally (about 15-20 minutes).

4. Assemble the Sandwich

  1. Bottom Layer: Place a slice of sourdough bread on your work surface. Add a layer of fried crispy onions.
  2. Cheese & Brisket: Add two slices of Colby Jack cheese, four slices of brisket, and the caramelized onions. Drizzle with BBQ sauce.
  3. Top Layer: Add two slices of Provolone cheese and cap it with another slice of sourdough bread.

5. Toast the Melt

  1. Heat a cast iron skillet over medium heat and add a pat of butter.
  2. Place the assembled sandwich in the skillet and toast for 3-4 minutes per side, pressing lightly with a spatula, until both sides are golden brown and the cheese is melted.

Serving Suggestions

  • Pair with a side of coleslaw, sweet potato fries, or baked beans for a complete BBQ-inspired meal.
  • Serve with extra BBQ sauce on the side for dipping.

Tips for Perfect Brisket Melts

  • Maintain Smoker Temperature: Consistency is key to achieving tender, smoky brisket.
  • Rest the Brisket: Never skip the resting step—it’s essential for juicy, flavorful meat.
  • Use High-Quality Bread: Sourdough holds up well to the hearty filling and gives a great crunch.

Final Thoughts

This BBQ Brisket Melt is a next-level sandwich that’s perfect for any brisket lover. The combination of tender, smoky meat, melty cheese, and caramelized onions will leave you craving more. Whether for a casual lunch or an indulgent dinner, this melt is a guaranteed crowd-pleaser.

Try it out, and let me know how it turns out in the comments below! 🍖✨