This Copycat Arby's Beef N' Cheddar is my at-home shortcut to a nostalgic fast-food favorite. I fell in love with the original as a teenager: the warm, tender roast beef folded into an onion roll, a creamy American cheese sauce pooling over the meat, and that slightly sweet, tangy dressing tying everything together. I recreated it after a long week when I wanted the exact same flavors without leaving home. The result? Comforting, quick, and remarkably close to the real thing — perfect for a busy weeknight or an indulgent weekend lunch.

I first tested this version after asking my deli to slice a roast beef extra thin. The technique is simple: warm the meat gently so it stays juicy, melt the cheese into a smooth sauce with a splash of milk, and whisk a homemade copy of Arby's signature dressing that brightens the sandwich. What makes it special is the balance: tender beef, creamy cheese, and a sauce with a little tang and garlic. It’s also fast — you can have four sandwiches ready in under 10 minutes, which makes it my go-to when friends drop by unannounced.

Ingredients

• Onion buns: Use four fresh onion rolls for the best aromatic base; look for soft, slightly sweet rolls in the bakery section or use plain hamburger buns if unavailable.
• Roast beef: One pound of thinly sliced deli roast beef is essential for that diner texture; ask the deli to slice it extra thin or buy pre-sliced for even heating.
• American cheese: Five slices of American cheese give the right melt and color; Velveeta or shredded mild cheddar are acceptable substitutes if you prefer a smoother sauce.
• Milk: Three tablespoons of whole milk smooths the cheese into a saucy consistency; skim or 2% will work but results will be slightly less rich.
• Garlic powder and black pepper: A quarter teaspoon of garlic powder in the sauce plus a pinch of black pepper adds subtle savory depth; fresh garlic is not recommended here because it alters the smooth texture.
• Signature sauce: Half a cup ketchup, two teaspoons water, quarter teaspoon garlic powder, quarter teaspoon onion powder, and a pinch of salt combine into a tangy, slightly sweet dressing that mimics Arby's Catalina-style sauce.

Instructions

Warm the beef: Heat a large skillet over medium heat. Add the thinly sliced roast beef in an even layer, cover with a lid, then reduce the heat to medium-low. Steam for 2 to 3 minutes — you want the slices hot and pliable, not crisped. The lid traps steam to heat quickly and preserve moisture; avoid high heat that dries the edges. Make the signature sauce: While the meat warms, whisk together 1/2 cup ketchup, 2 teaspoons water, 1/4 teaspoon garlic powder, 1/4 teaspoon onion powder, and a pinch of salt in a small bowl until smooth. Taste and adjust: add a touch more water for a thinner sauce, or a dash of sugar if you prefer it sweeter. Spread a light layer on both cut sides of the onion buns. Prepare the cheese sauce: Set a small saucepan over medium-low heat. Add five slices of American cheese broken into pieces, 3 tablespoons milk, 1/4 teaspoon garlic powder, and a grind of black pepper. Stir frequently until the cheese melts into a smooth, glossy sauce, about 3 to 4 minutes. Keep the heat low to prevent separation; if the sauce looks grainy, add a tablespoon more milk and whisk vigorously. Assemble the sandwiches: Lay warm roast beef on the bottom halves of the buns. Spoon or drizzle the cheese sauce over the meat, add a little extra signature sauce if desired, and cap with the top bun. Serve immediately with your favorite fries.

Storage Tips

Store leftover roast beef in an airtight container in the refrigerator for up to 3 days. Keep the cheese sauce in a separate sealed jar; it will thicken when chilled — reheat gently in a small saucepan over low heat with a splash of milk to bring it back to pourable consistency. Onion buns keep best at room temperature for a day; for longer storage freeze them in a zip-top bag and thaw on the counter before assembling. When reheating the assembled sandwich, use a 325°F oven for 6 to 8 minutes to warm through without drying, covering the top loosely with foil.

Ingredient Substitutions

If you don’t have American cheese, Velveeta melts extremely smoothly and is the closest processed-cheese alternative; shredded mild cheddar works too but will be slightly less creamy. For a dairy-free version, use a dairy-free cheese that melts well and swap milk for a plant-based milk with neutral flavor. If you want to reduce sodium, purchase low-sodium deli roast beef and low-sodium ketchup; note the flavor will be milder, so increase aromatic spices like a pinch more garlic powder. Use brioche buns for a richer finish or plain potato rolls if you prefer less onion flavor.

Serving Suggestions

Serve these sandwiches with classic curly fries to evoke the Arby's experience, or pair with a crisp green salad to balance the richness. For a loaded plate, add pickles or thin-sliced red onions for brightness, or a side of coleslaw for crunch. Garnish with a sprinkle of cracked black pepper over the cheese and a light brushing of melted butter on the bun before toasting to add shine and flavor. These sandwiches also pair well with a cold iced tea or a crisp lager.

Cultural Background

The original Beef 'N Cheddar is a signature menu item from a major American sandwich chain known for roast beef and fast-service sandwiches. The combination of warm roast beef and a creamy processed-cheese sauce reflects mid-20th century American tastes that favored convenience and comforting textures. Many regional delis and diners developed similar melted-cheese-over-roast-beef plates, and this copycat version celebrates that nostalgic flavor profile while letting you control ingredients at home.

Seasonal Adaptations

In cooler months, add a smear of horseradish mayo for warming heat, or swap the signature sauce for a roasted pepper spread in summer to keep the sandwich bright. Fall is a great time to serve with roasted root-vegetable hash on the side. For holiday gatherings, cut sandwiches into sliders and serve on a platter with extra dipping sauce for guests. Lighten it in spring by using mixed greens and a lighter cheese sauce with milk substituted by half-and-half for richness without heaviness.

Meal Prep Tips

For make-ahead lunches, portion meat into individual containers and ladle cheese sauce into small jars. Toast buns lightly just before serving to avoid sogginess. If preparing for a crowd, warm the roast beef in a large covered skillet or on a sheet pan in a low oven, then assemble plates assembly-line style. Use insulated containers to keep assembled sandwiches warm for short transport, and pack sauce separately in a leak-proof jar.

Bringing this sandwich home means you can recreate the fond memories of a favorite chain while making small improvements — better bread, fresher meat, and a sauce tuned to your taste. Try it once and you’ll see why it’s a fast and satisfying pick-me-up.

Enjoy building your own Beef N' Cheddar at home — and don’t forget the fries.