Melt-in-Your-Mouth Chuck Roast Sandwich with Crispy Onions

Piled with tender shredded chuck roast, melty cheese, homemade barbecue sauce, peppery arugula, and crisp fried onions, these sandwiches are rich, satisfying, and easy to prepare ahead.

Ingredients

For the barbecue sauce

• 1 1/2 cups ketchup
• 1 3/4 cups distilled white vinegar
• 3/4 cup packed brown sugar
• 1/4 cup honey
• 1 1/2 tablespoons Worcestershire sauce
• Salt and pepper, to taste

For the sandwich

• 2 1/2 pounds chuck roast, cut into 4 large chunks
• Salt and pepper, to taste
• 3 tablespoons olive oil
• 4 cups low-sodium beef stock
• 1 large loaf ciabatta or soft Italian bread (or soft rolls)
• 1 large onion, sliced
• 2 tablespoons cornstarch
• Olive oil for frying (or a neutral oil with a high smoke point)
• 1/2 pound sliced American muenster cheese (or mozzarella)
• 2 cups arugula

Units: US Customary (Metric equivalents may be used as desired).

Instructions

Make the barbecue sauce

1. Combine the ketchup, vinegar, brown sugar, honey, and Worcestershire sauce in a saucepan. Bring to a gentle simmer, stirring frequently. Taste and adjust with salt and pepper. Remove from heat and set aside.

Braise the chuck roast and prepare the onions

1. Preheat the oven to 300°F and arrange a rack to accommodate a large Dutch oven.
2. Season the chuck roast pieces generously with salt and pepper on all sides.
3. Heat a large Dutch oven over medium heat with 3 tablespoons olive oil. Sear the chuck roast pieces on all sides until browned, then transfer them to a plate.
4. Add the beef stock to the pot, bring to a boil, and scrape up any browned bits from the bottom with a wooden spoon. Turn off the heat, stir in 1 cup of the prepared barbecue sauce, return the beef to the pot, and cover.
5. Place the covered pot in the preheated oven and braise until the beef is fork-tender and easily shreds, about 3 hours. Oven times vary—continue cooking until shreddable.
6. While the beef braises, toss the sliced onions with the cornstarch and let them sit for about 10 minutes so the coating adheres.
7. Pour oil into a high-walled pan to about 1″ depth and heat to approximately 370°F (or until a piece of onion sizzles and crisps). Fry the onions in batches until golden brown and crisp. Use a slotted spoon to transfer them to a paper towel-lined tray to drain and season lightly with salt.
8. When the beef is done, remove the pieces and place them in a bowl. Shred with two forks or your hands, then mix in 1/2 cup of the reserved braising liquid and 1/2 cup of the barbecue sauce to moisten and flavor the meat.
9. Slice the loaf of bread open and place it on a baking sheet. Layer the shredded beef over the bottom half, top with slices of muenster cheese, and warm in the oven a few minutes to melt the cheese.
10. Remove from the oven, spread a layer of barbecue sauce on the top half of the bread, add arugula, and sprinkle generously with the crispy onions. Close the sandwich, slice into portions, and serve immediately.

Notes

• Servings: Makes 4 large sandwiches or 6 smaller sandwiches.
• Bread choice: A softer bread is recommended so it soaks up juices and remains easy to bite through. Save crusty loaves for sandwiches where a firmer crust is preferred.
• Doneness: The 3-hour braise time is an estimate. Cook until the roast is fall-apart tender and easily shredded with a fork; if it’s not done at 3 hours, continue cooking and check periodically.
• Slow cooker option: You can braise the chuck roast in a slow cooker — expect about 8–9 hours on low or 4–5 hours on high until shreddable.
• Make-ahead and storage: Braised beef can be refrigerated for up to 3 days and reheats well. Crispy onions keep best in a sealed container for up to 3 days; re-crisp them briefly in the oven if needed. Leftover barbecue sauce will keep in the refrigerator for up to 2 weeks.
• Cheese substitutions: Use mozzarella or a mild provolone if you prefer a different melting cheese.

Nutrition

Nutrition information is automatically calculated and should be used as an approximation.