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This Arbys roast beef sandwich copycat recipe delivers the iconic smoky-spiced beef and crispy potato topping you crave at home. The secret lies in slow-cooking beef brisket until fork-tender, then slicing it against the grain for that signature shredded texture. Every bite combines perfectly seasoned beef with a golden, slightly crispy potato topping that mimics the chain's signature style.
What sets this recipe apart is the balance of flavors—smoky paprika and garlic powder infuse the beef while the potato topping achieves that ideal crispy-yet-tender texture through careful baking. The homemade horseradish sauce ties everything together with its signature tangy kick. This isn't just a copycat; it's a restaurant-quality sandwich you can make in your own kitchen.
The beef emerges tender enough to shred easily, while the potato topping develops a golden crust that stays crispy even after being topped with beef. Each component comes together in a toasted bun that holds up perfectly to the generous fillings. The result is a sandwich that's dangerously close to the original—so close, you might forget you're not ordering out.
Perfect for game day, lunch dates, or satisfying that fast-food craving without the drive-thru. The recipe scales easily for feeding a crowd, and the leftovers reheat beautifully. Let's get started on recreating this American classic in your kitchen.
Ingredients for arbys roast beef sandwich copycat
Fourteen ingredients for a restaurant-quality sandwich that'll fool even the biggest Arby's fans.
| Ingredient | Amount | Notes |
|---|---|---|
| Beef Brisket 🥩 | 2 lb | Flat cut preferred, trimmed of fat |
| Yellow Onion 🧅 | 1 whole | Medium-sized, sliced thick |
| Garlic Cloves 🧄 | 6 cloves | Peeled, smashed slightly |
| Smoked Paprika 🌶️ | 2 tbsp | For authentic smoky flavor |
| Garlic Powder 🧄 | 1 tbsp | Enhances the beef seasoning |
| Onion Powder 🧅 | 1 tbsp | Adds depth to the rub |
| Ground Black Pepper 🌶️ | 1 tbsp | Freshly ground preferred |
| Salt 🧂 | 1 ½ tbsp | Kosher salt for even seasoning |
| Russet Potatoes 🥔 | 2 lb | Medium-sized, cut into chunks |
| All-Purpose Flour 🌾 | ½ cup | For potato topping crispiness |
| Butter 🧈 | ½ cup | Unsalted, melted for flavor |
| Horseradish 🌿 | ¼ cup | Prepared, for signature sauce |
| Mayonnaise 🥫 | ¼ cup | For creamy sauce base |
| White Vinegar 💧 | 1 tbsp | For tangy sauce balance |
| Sesame Seed Buns 🍞 | 4 whole | Toasted for sandwich assembly |
The beef is everything here—brisket gives that signature tender texture when slow-cooked. Grab the flat cut from the butcher counter if you can; it's leaner and more flavorful. Costco or Kroger usually have it pre-packaged, but ask for it to be trimmed of excess fat. The potatoes? Russets are your best bet—they're starchy enough to hold up to baking without turning mushy. I always buy a few extra pounds and keep them in the fridge for other recipes too.
No smoked paprika? Regular paprika plus a pinch of liquid smoke works in a pinch. The horseradish sauce is where the magic happens—prepared horseradish from the jar is perfect, but fresh root is ideal if you're feeling fancy. Short on time? Substitute Dijon mustard for the mayo in the sauce, though it won't be exactly the same. The potato topping needs that flour for crispiness, but if you're gluten-free, almond flour works too. Just don't skip the butter—it's what makes it taste like Arby's.
The beef keeps for 3 days in the fridge, but it's even better reheated the next day. The potato topping reheats well too—just pop it in the oven at 375°F for 5-10 minutes. Make a double batch of the sauce—it disappears fast. I always slice the beef thin against the grain and portion it out in containers so I can assemble sandwiches in seconds. The buns toast best in a toaster oven or skillet—don't skip this step!
Why You'll Love This Recipe
- One-Pan Magic: I swear by this recipe because it’s that simple—just brisket, onions, and a handful of spices slow-cooked until tender. No chopping mountains of veggies or fussing with marinades; the onions caramelize right there while the beef falls apart at the touch of a fork.
- Smoky Garlic Bomb: Between the smoked paprika’s deep warmth and the garlic powder’s punch, this beef is ridiculously flavorful. The brisket soaks up those spices like a sponge, giving you that signature Arbys tang without the mystery meat.
- Lunchbox Legend: This isn’t just for sandwiches—slice it for wraps, toss it into salads, or pile it on toast for a lazy breakfast. Honestly, I’ve even used it in tacos when I’m feeling wild, and it never lets me down.
- Budget Win: A pound of brisket stretches across multiple meals, and the spices cost pennies. Between us, this is the kind of recipe that makes grocery day exciting because you’re not just feeding your family—you’re feeding them well.
Step-by-step instructions for Arbys roast beef sandwich copycat recipe
Here's how to recreate that iconic smoky beef and crispy potato topping at home—just like Arby's.
Prepare the Smoky-Spiced Beef
In a small bowl, combine the 2 tbsp smoked paprika, 1 tbsp garlic powder, 1 tbsp onion powder, 1 tbsp ground black pepper, and 1.5 tbsp salt. This dry rub is what gives the beef that signature smoky depth. Pat the 2 lb beef brisket dry with paper towels—this ensures a better sear and crispier exterior.
Rub the spice mixture all over the brisket, pressing it into the meat so it sticks. Let it sit at room temperature for 30 minutes while you prep the rest. This step is crucial—it allows the rub to penetrate and the meat to cook more evenly. Meanwhile, slice the 1 whole yellow onion into thick rounds and set aside.
Cook the Beef Low and Slow
Preheat your oven to 300°F. Place the seasoned brisket in a roasting pan, fat-side up, and cover tightly with aluminum foil. Roast for 3 hours, checking occasionally to ensure the foil isn't sticking. This slow cook method keeps the beef tender and juicy.
After 3 hours, remove the foil and increase the oven temperature to 375°F. Roast uncovered for another 30-45 minutes until the beef reaches an internal temperature of 195°F and is fork-tender. Let it rest for 15 minutes before slicing thinly against the grain. The resting period is key—it allows the juices to redistribute, ensuring every bite is moist and flavorful.
Make the Crispy Potato Topping
While the beef cooks, peel and cut the 2 lb russet potatoes into 1-inch chunks. Boil them in salted water for 10-12 minutes until fork-tender but not falling apart. Drain well and transfer to a large bowl.
In a separate bowl, mix the 0.5 cup all-purpose flour and 1 tbsp salt. Toss the hot potatoes in the flour mixture until evenly coated. Heat 0.25 cup butter in a large skillet over medium-high heat until melted and foaming. Add the floured potatoes in a single layer and cook for 8-10 minutes, stirring occasionally, until golden brown and crispy. Transfer to a paper towel-lined plate to drain excess oil.
Assemble the Signature Sauce
In a small bowl, whisk together the 0.25 cup mayonnaise, 0.25 cup horseradish, and 1 tbsp white vinegar until smooth. This tangy, creamy sauce is the perfect balance to the smoky beef. Taste and adjust the seasoning with a pinch of salt or pepper if needed.
Toast the 4 whole sesame seed buns lightly in a toaster or oven until golden. Spread a generous layer of the sauce on each bun. Pile the sliced beef onto the bottom half of each bun, then top with the crispy potato topping. Serve immediately for that classic Arby's experience at home.
Pro Tips For Making Arbys Roast Beef Sandwich Copycat
- CRUSH THE ONIONS: Dice them small—think rice-sized pieces, not chunky. I used to cut them like I was prepping a salad, but the sauce needs those tiny bits to dissolve and mingle with the beef. If you’re impatient, pulse them in a food processor for 3 seconds, but don’t overdo it—you’re not making onion powder.
- SALT THE BEEF BEFORE SEARING: Generously coat the brisket with salt before hitting the pan—this isn’t just for flavor, it’s for texture. The salt draws out moisture, which caramelizes into a crust when you sear. Skip this, and you’ll end up with a mealy edge instead of that crispy, restaurant-worthy bite.
- LOW AND SLOW AFTER SEARING: Once the brisket hits the oven, resist the urge to crank the heat. 275°F is the sweet spot—it’s slow enough to render fat without drying out the meat. I learned this after one batch turned out like shoe leather. Use a meat thermometer; pull it at 195°F internal temp, even if it feels underdone.
- UPGRADE WITH BUTTER AND HORSERADISH: After the onions caramelize, toss in 2 tablespoons of butter and 1 teaspoon of prepared horseradish (yes, even if the recipe doesn’t say it). The butter adds richness, and the horseradish cuts through the fat—just like Arby’s. It’s a 30-second tweak that makes the sauce sing. (Your sandwich will taste like you’ve been in the business for years.)
Essential equipment for this recipe
Slow-Cooker Essentials
Your slow cooker is the MVP for tenderizing that 2 lb beef brisket—I swear by a 6-quart Hamilton Beach for even heat distribution. Set it to Low for 8 hours (or High for 5-6 hours) with the brisket submerged in 1 cup beef broth and the sliced yellow onion. The liquid keeps the meat moist while the slow cooker does all the work. 🌡️
No slow cooker? A Dutch oven on the stovetop works just as well. Fill it halfway with water, bring to a simmer, then reduce to a gentle bubble. Cover and cook on low heat for 6-7 hours, checking occasionally to ensure the liquid doesn’t evaporate completely. The key is patience—rushing ruins the texture.
Slicing Tools
A sharp carving knife is non-negotiable for slicing the beef against the grain. I use a Wüsthof 8-inch—its hollow-ground edge glides through the tender meat without tearing. Slice ¼-inch thick pieces for that signature shredded texture. If your knife isn’t sharp enough, the beef will fray, and the sandwich will fall apart. 🔪
For extra precision, place the rested brisket on a cutting board and use your non-dominant hand to guide the knife along the grain’s direction. A meat slicer (like the OXO Good Grips) is a game-changer if you’re making this often—it ensures uniform slices every time.
Potato Topping Pan
The 12-inch cast-iron skillet is your best friend for crispy potato topping. Preheat it over medium-high heat until smoking hot before adding the floured potatoes. Cast iron retains heat like nothing else, creating that golden, crispy crust Arby’s is known for. If you don’t have cast iron, a non-stick skillet works too—just avoid overcrowding the pan. 🍳
For even crispiness, spread the potatoes in a single layer and resist the urge to stir too often. Let them develop a crust for 2-3 minutes on each side. If they stick, your pan isn’t hot enough—give it another 2 minutes to heat up properly.
Sauce Mixing Bowl
A small mixing bowl (like a Pyrex glass bowl) is perfect for whipping up the horseradish sauce. The smooth sides make it easy to whisk the mayonnaise, horseradish, and vinegar into a creamy consistency. Glass bowls also let you check the color—it should be a vibrant pale yellow with no streaks. 🥄
For extra tang, add ½ tsp Dijon mustard to the sauce. If you’re feeling adventurous, a dash of hot sauce (like Frank’s RedHot) adds a subtle kick. Store leftovers in an airtight container in the fridge for up to 5 days—the flavors only get better with time.
Bun Toasting Tools
Toast your sesame seed buns in a toaster oven or skillet for the best results. A toaster oven gives even browning, while a skillet adds a crispy, buttery crust. Heat 1 tbsp butter in the skillet over medium heat, then toast each bun for 1-2 minutes per side until golden. 🍞
No toaster oven? A broiler works in a pinch—place buns on a baking sheet and broil for 1-2 minutes, watching closely to avoid burning. For extra crispiness, brush the toasted buns with a little melted butter before assembling the sandwiches.
Nutrition facts
Frequently asked questions
Why does slicing the beef against the grain matter?
Slicing against the grain creates shorter muscle fibers, making each bite more tender and easier to chew. This technique is key to replicating Arby's signature texture—if you slice with the grain, the beef will be tough and stringy. For best results, let the beef rest for 15 minutes after cooking before slicing ¼-inch thick pieces.
Can I make this recipe without a slow cooker?
Use a Dutch oven on the stovetop instead. Fill it halfway with water, bring to a simmer, then reduce to a gentle bubble and cook covered for 6-7 hours on low heat. The goal is slow, even cooking—just like the slow cooker method. Patience is key for tender beef!
How do I make the potato topping extra crispy?
Heat your cast-iron skillet until smoking hot before adding the potatoes. Spread them in a single layer and avoid stirring too often—let them develop a golden crust for 2-3 minutes per side. If they stick, your pan isn't hot enough. For extra crunch, toss the cooked potatoes in a bit of cornstarch before serving.
What if I don't have sesame seed buns?
Any soft, toasted bun works—like potato buns or even hoagie rolls. Toast them lightly in a skillet with butter for that classic Arby's texture. If you're gluten-free, use a gluten-free sandwich bun and toast it until crispy. The key is a sturdy bun that can hold up to the fillings!
Can I prep the beef ahead of time?
Yes! Cook the beef up to 3 days ahead and store it in an airtight container in the fridge. Reheat gently in the oven at 300°F until warmed through. The potato topping reheats well too—just pop it in the oven for 5-10 minutes at 375°F to restore crispiness. Assemble the sandwiches fresh for the best experience.