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Smoked Beef Brisket Melts Recipe

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4.8 from 148 reviews

This recipe for BBQ Brisket Melts features tender, slow-smoked brisket layered with crispy fried onions and melted cheeses on toasted sourdough bread. The brisket is seasoned with a pepper-forward rub and slow-smoked over hickory wood pellets, then wrapped and cooked to perfection before being assembled into savory, cheesy melts. The combination of smoky meat, caramelized onions, and toasted bread creates an indulgent sandwich perfect for a hearty meal.

Ingredients

For the Brisket

  • 1 brisket (about 8-10 lbs)
  • Mustard (for binding, about 2-3 tablespoons)
  • Pepper-forward brisket rub (approximately 1/4 cup)
  • Hickory wood pellets (for smoking)
  • Apple cider vinegar (about 1/4 cup, for wrapping)
  • Beef tallow (2-3 tablespoons, for wrapping)

For the Sandwich Assembly

  • Sourdough bread (8 slices)
  • Colby jack cheese (8 slices)
  • Provolone cheese (8 slices)
  • Fried crispy onions (about 1 cup)
  • Unsalted butter (for toasting, about 2-3 tablespoons)
  • Avocado oil (1 tablespoon, for caramelizing onions)
  • Diced onions (1 medium onion)
  • BBQ sauce (to taste, approximately 1/2 cup)

Instructions

  1. Prepare the Brisket: Trim any excess fat from the brisket. Apply a thin layer of mustard all over the brisket as a binder to help the rub adhere. Generously season the brisket with your favorite pepper-forward rub. Place the brisket in the refrigerator and let it rest for 1-2 hours to allow the flavors to penetrate.
  2. Initial Smoking: Preheat your pellet smoker to 210°F and use hickory wood pellets for a deep smoky flavor. Place the brisket on the smoker and cook for 9-10 hours, smoking until the internal temperature reaches 165-170°F.
  3. Wrap and Continue Smoking: Once the brisket reaches the target temperature, wrap it tightly in butcher paper along with apple cider vinegar and beef tallow to keep it moist and tender. Increase the smoker temperature to 250°F, then continue smoking the wrapped brisket until it reaches an internal temperature of 204-206°F.
  4. Rest the Brisket: Remove the brisket from the smoker and let it rest for 2-3 hours. This resting period allows the juices to redistribute, ensuring a moist and flavorful cut when sliced.
  5. Caramelize the Onions: While the brisket is resting, heat avocado oil and butter in a skillet over medium heat. Add diced onions and sauté them slowly until they are golden brown and caramelized, developing a rich, sweet flavor.
  6. Assemble the Sandwiches: Layer fried crispy onions, thinly sliced brisket, Colby jack cheese, provolone cheese, and BBQ sauce between slices of toasted sourdough bread. Use enough filling to get a hearty melt.
  7. Toast the Melts: Heat a cast iron skillet over medium heat. Add unsalted butter to the pan, then place the assembled sandwiches in the skillet. Toast them on medium heat until the bread is golden brown and crispy, and the cheeses have melted completely.

Notes

  • Allowing the brisket to rest is crucial to maintain moisture and improve tenderness.
  • Using butcher paper instead of foil helps retain smoke flavor while keeping the brisket moist.
  • Feel free to adjust the amount of BBQ sauce according to your taste preferences.
  • For best results, use a reliable meat thermometer to monitor the internal temperature accurately.
  • Caramelizing the onions slowly is important to develop their natural sweetness without burning.
  • Toast the sandwiches slowly on medium heat to avoid burning the bread before the cheese melts.