Indulge in the delightful world of BBQ Brisket Melts, where tender smoked brisket meets gooey cheese and crispy toppings. This sandwich is perfect for gatherings, casual lunches, or simply satisfying cravings. With its rich flavors and hearty ingredients, BBQ Brisket Melts are a delicious twist on traditional barbecue that will impress your family and friends.

Why You’ll Love This BBQ Brisket Melts
BBQ Brisket Melts aren’t just another sandwich; they offer a unique combination of flavors and textures that make them stand out.
- Deliciously Flavorful: The smoked brisket combined with cheese and caramelized onions creates an explosion of taste in every bite.
- Hearty and Satisfying: This melt is packed with protein and flavor, making it a filling meal perfect for any time of day.
- Easy to Customize: Feel free to add your favorite toppings or sauces, allowing you to personalize each melt according to your taste.
- Great for Entertaining: Serve these melts at parties or gatherings, and watch them disappear quickly as guests rave about their deliciousness.
- Comfort Food Classic: A perfect mix of savory goodness that brings warmth and comfort, ideal for cozy nights in.
Tools and Preparation
To create the perfect BBQ Brisket Melts, having the right tools will make the process smoother. Below are some essential tools needed.
Essential Tools and Equipment
- Pellet smoker
- Cast iron skillet
- Sharp knife
- Cutting board
Importance of Each Tool
- Pellet smoker: Provides consistent heat and smoky flavor, essential for achieving perfectly cooked brisket.
- Cast iron skillet: Ideal for toasting the sandwich evenly while keeping it crispy on the outside.
- Sharp knife: Ensures clean cuts when slicing the brisket and onions, enhancing presentation.
- Cutting board: Offers a safe surface for prepping all ingredients without damaging your countertops.
Ingredients
For the Brisket
- Brisket
- Mustard as a binder
- Favorite brisket rub (preferably pepper-forward)
- Hickory pellets for smoking
- Apple cider vinegar
- Beef tallow (3-4 tablespoons)
For the Onions
- 2 whole onions
- Avocado oil (2 tablespoons)
- Kosher salt (1 tablespoon)
- Unsalted butter (2 tablespoons plus more for toasting)
For Assembling the Melt
- Sourdough bread
- Fried crispy onions
- Colby jack cheese (2 slices)
- Provolone cheese (2 slices)
- Favorite BBQ sauce

How to Make BBQ Brisket Melts
Step 1: Prepare the Brisket
- Trim excess fat from the brisket.
- Apply mustard all over as a binder.
- Generously season with your pepper-forward brisket rub.
- Refrigerate for 1-2 hours to allow flavors to penetrate.
Step 2: Smoke the Brisket
- Preheat your pellet smoker to 210 degrees Fahrenheit.
- Place hickory pellets in the smoker’s hopper along with a water pan underneath it.
- Smoke the brisket for 9-10 hours until it reaches an internal temperature of 165-170 degrees Fahrenheit.
Step 3: Wrap and Continue Smoking
- Wrap the brisket in butcher’s paper with apple cider vinegar and beef tallow.
- Increase the smoker temperature to 250 degrees Fahrenheit.
- Continue smoking until it reaches an internal temperature of 204-206 degrees Fahrenheit.
Step 4: Rest the Brisket
- Remove from smoker and keep wrapped in a cooler for 2-3 hours to rest properly.
Step 5: Caramelize Onions
- Dice two whole onions.
- In a skillet, heat avocado oil over medium heat.
- Add diced onions along with kosher salt and butter; sauté until caramelized.
Step 6: Assemble Your Melt
- Take sourdough bread slices; layer bottom slice with fried onions, Colby jack cheese, sliced brisket, caramelized onions, BBQ sauce, provolone cheese, and top bun.
Step 7: Toast Your Sandwich
- Heat a cast iron skillet over medium heat with butter.
- Place assembled sandwich in skillet; toast for about 3-4 minutes on one side before flipping once until golden brown.
Enjoy crafting these BBQ Brisket Melts that encapsulate comfort food at its finest!
How to Serve BBQ Brisket Melts
Serving BBQ Brisket Melts is all about enhancing the rich flavors and textures of this delightful sandwich. Pairing it with the right sides and drinks can elevate your dining experience.
Classic Pairings
- Pickles – The acidity from pickles cuts through the richness of the brisket.
- Coleslaw – A refreshing crunch that complements the melt’s gooey texture.
Creative Twists
- Guacamole – Adds a creamy layer that pairs well with smoky brisket.
- Spicy Jalapeños – For those who love heat, sliced jalapeños bring a fiery kick.
Perfect Beverages
- Craft Beer – A hoppy IPA enhances the smoky flavors of the brisket.
- Iced Tea – A sweetened iced tea balances the savory notes of your melt.
How to Perfect BBQ Brisket Melts
To achieve the ultimate BBQ Brisket Melt, consider these essential tips for flavor and texture.
- Bold seasoning – Use a robust, pepper-forward rub to enhance the brisket’s flavor profile.
- Low and slow cooking – Smoking at low temperatures ensures tender, juicy meat that’s full of flavor.
- Resting time – Allowing the brisket to rest after cooking helps retain moisture for a juicy bite.
- Quality cheese – Opt for high-quality cheese like Colby jack and provolone for that perfect meltiness.
- Caramelization – Take your time caramelizing onions; it adds sweetness that balances savory elements.
- Sourdough bread – Choose fresh sourdough for its tangy flavor and sturdy structure to hold all components together.

Best Side Dishes for BBQ Brisket Melts
Pairing your BBQ Brisket Melts with complementary side dishes can make your meal even more enjoyable. Here are some great options:
- French Fries – Crispy fries are a classic choice that everyone loves; try seasoning them with garlic or herbs.
- Potato Salad – A creamy potato salad brings comfort food vibes, making it a perfect companion for your melt.
- Corn on the Cob – Grilled corn adds sweetness and char, enhancing your barbecue experience.
- Baked Beans – Rich and hearty baked beans are flavorful and add a nice contrast to the sandwich.
- Macaroni and Cheese – This cheesy dish is always a hit, providing additional comfort alongside your melt.
- Chips and Salsa – A fresh salsa adds brightness, while tortilla chips contribute crunch to your meal.
Common Mistakes to Avoid
When making BBQ Brisket Melts, it’s easy to overlook some important steps that can affect the final result. Here are common mistakes to avoid:
- Skipping the rub: Not seasoning your brisket with a proper rub can lead to bland flavors. Always apply a generous amount of your favorite pepper-forward brisket rub.
- Inadequate smoking time: Rushing the smoking process can result in tough meat. Ensure you smoke the brisket for the full 9-10 hours at the right temperature for tenderness.
- Not resting the brisket: Cutting into the brisket too soon can release juices, making it dry. Rest it wrapped in butcher paper for 2-3 hours to retain moisture.
- Using low-quality bread: Choosing inferior bread can diminish your sandwich’s overall taste and texture. Opt for fresh sourdough bread for a better melt experience.
- Overcooking onions: Burning or undercooking caramelized onions can affect flavor. Sauté them slowly until golden brown for optimal sweetness.
Storage & Reheating Instructions
Refrigerator Storage
- Store leftover BBQ Brisket Melts in an airtight container.
- They will stay fresh for up to 3 days in the refrigerator.
Freezing Instructions
- Wrap individual sandwiches tightly in plastic wrap or foil and place them in a freezer-safe bag.
- They can be frozen for up to 2 months.
Reheating Instructions
- Oven: Preheat your oven to 350°F (175°C). Wrap sandwiches in foil and heat for about 15-20 minutes, ensuring they stay moist.
- Microwave: Place on a microwave-safe plate and cover with a damp paper towel. Heat in short bursts of 30 seconds until warmed through.
- Stovetop: Heat on medium in a skillet with a little butter. Flip occasionally until both sides are crispy and heated through.

Frequently Asked Questions
What type of cheese is best for BBQ Brisket Melts?
Colby jack and provolone cheese are great choices due to their melting properties and complementary flavors.
Can I use leftover brisket for these melts?
Absolutely! Using leftover smoked brisket is an excellent way to make quick and delicious BBQ Brisket Melts.
How do I customize my BBQ Brisket Melts?
Feel free to add ingredients like jalapeños, pickles, or different cheeses based on your preferences!
What sides pair well with BBQ Brisket Melts?
Consider serving these melts with coleslaw, potato chips, or baked beans for a complete meal.
Final Thoughts
BBQ Brisket Melts are not only indulgent but also versatile, making them perfect for lunch or dinner. This recipe allows room for creativity; feel free to experiment with different toppings and sides. Give this delicious sandwich a try; you won’t be disappointed!

BBQ Brisket Melts
- Total Time: 10 hours 30 minutes
- Yield: Serves 4 sandwiches
Description
BBQ Brisket Melts are a mouthwatering combination of tender, smoky brisket, melted cheese, and caramelized onions all nestled between slices of crispy sourdough bread. This delicious sandwich is perfect for any occasion, from casual lunches to festive gatherings. The rich flavors and satisfying textures will impress your family and friends, making it a must-try recipe for comfort food enthusiasts. With easy customization options for toppings and sauces, you can create your ideal melt every time.
Ingredients
- Brisket
- Mustard (binder)
- Brisket rub (pepper-forward)
- Hickory pellets (for smoking)
- Sourdough bread
- Colby jack cheese
- Provolone cheese
- Caramelized onions
- BBQ sauce
Instructions
- Prepare brisket by trimming excess fat, applying mustard as a binder, and seasoning generously with brisket rub.
- Smoke the brisket at 210°F for 9-10 hours until it reaches an internal temperature of 165-170°F.
- Wrap the brisket in butcher paper with apple cider vinegar and beef tallow, then continue smoking at 250°F until it reaches 204-206°F.
- Rest the brisket in a cooler for 2-3 hours before slicing.
- Caramelize diced onions in avocado oil, kosher salt, and butter until golden brown.
- Assemble the melt with layers of fried onions, sliced brisket, cheeses, and BBQ sauce on sourdough bread.
- Toast the assembled sandwich in a buttered cast iron skillet until golden brown.
- Prep Time: 30 minutes
- Cook Time: 10 hours
- Category: Main
- Method: Smoking, Toasting
- Cuisine: American
Nutrition
- Serving Size: 1 sandwich (approx. 300g)
- Calories: 680
- Sugar: 6g
- Sodium: 1520mg
- Fat: 38g
- Saturated Fat: 18g
- Unsaturated Fat: 15g
- Trans Fat: 1g
- Carbohydrates: 45g
- Fiber: 3g
- Protein: 42g
- Cholesterol: 125mg
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