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Smoky BBQ Brisket Melts have a magical power to stop conversations mid-sentence. Imagine smoky brisket, golden sourdough, gooey cheese, and crispy onions all combined for the kind of crave-worthy sandwich you dream about all week long.
My crew fell for these brisket melts the first time I served them at family game night. Now, whenever I make brisket, everyone immediately asks if brisket melts are next on the menu.
Ingredients
- Whole brisket: Choose one with nice marbling for rich flavor
- Peppery BBQ rub: Makes a bold crust and balances the beef’s richness
- Hickory wood pellets: Infuse deep, robust smoke
- Sourdough bread: Firm and tangy enough to hold all those fillings without getting soggy
- Colby jack and provolone: The melty cheese combo that balances sharp and creamy
- Fried crispy onions: Layers in texture and sweet onion flavor
- Unsalted butter: Gives the bread that irresistible golden crust
Instructions
- Trim and Season:
- Remove any thickest fat so just a thin cap remains. Rub the brisket with mustard on all sides to help the seasoning stick. Cover the meat in pepper and spice-heavy BBQ rub, pressing it on. Chill covered for at least an hour to deepen the seasoning.
- Low and Slow Smoke:
- Set your smoker to 210 degrees. Add hickory wood pellets. Place the brisket fat side up and smoke low and slow for about nine hours until the internal temp reaches 165 to 170.
- Wrap and Finish:
- Once a dark bark forms, wrap the brisket tightly in butcher paper. Add a splash of apple cider vinegar and a spoon of beef tallow. Raise the smoker to 250 degrees and continue smoking until the brisket temp reads 204 to 206 for tenderness.
- Rest and Slice:
- Transfer the wrapped brisket to a cooler or warm oven (set to off). Rest at least two hours for juiciness. Slice against the grain.
- Caramelize the Onions:
- Dice onions and cook gently in a pan with avocado oil and butter on medium-low, stirring so onions turn deep gold and sweet.
- Assemble the Melts:
- Lay out thick slices of sourdough and spread with butter. On the unbuttered side, layer sliced brisket, cheese, fried onions, and BBQ sauce. Top with a second slice of bread, buttered side out.
- Toast to Perfection:
- Heat a cast iron skillet over medium. Grill sandwiches until crisp and the cheese turns gooey, flipping once. Serve hot.
The best part of making these is always that first slice into the rested brisket — the juices bead up and the smoky aroma fills the kitchen. My favorite touch is those crispy onions piled in, and my kids try to sneak extra straight from the pan every time.
Storage and Leftover Tips
Leftover brisket keeps in airtight containers in the fridge for up to four days and reheats well with a little broth or BBQ sauce. Any extra onions and cheese can be saved together for quick sandwiches or used with store-bought roast beef if you’re out of brisket. Sandwiches freeze best before griddling so you can pull one out and toast it fresh later.
Easy Ingredient Swaps
Cheddar or Swiss can stand in for other cheeses in a pinch. Try a sweet Hawaiian roll for a softer bite, or swap applewood or oak for hickory smoke if you like a lighter flavor.
Perfect Ways to Serve This
Serve with crunchy slaw or pickles for balance or with roasted potatoes or chips for comfort. For something special, drizzle spicy honey over the hot melt.
These brisket melts make even an ordinary day feel epic. Serve hot and watch them disappear fast!
Recipe Q&A
- → What cut of brisket works best for this sandwich?
Choose a whole brisket or flat cut for tender, sliceable results. Trim excess fat before seasoning and smoking.
- → Can I use a different type of bread?
Yes, while sourdough adds great texture, any sturdy bread like ciabatta or French loaf holds up well when toasted.
- → What is a good substitute if I don’t have a pellet smoker?
Oven roasting with smoked paprika or liquid smoke offers a smoky flavor profile without special equipment.
- → How do I keep the brisket juicy after smoking?
Wrap the brisket and let it rest for several hours after smoking. This helps redistribute moisture for a tender sandwich.
- → Can I use store-bought BBQ sauce?
Absolutely! Choose a flavor that complements smoked meats, such as sweet or tangy varieties, for best results.
- → How do I achieve a crispy sandwich exterior?
Butter the sourdough and toast in a cast iron skillet over medium heat to create an even, golden crust.