Arby’s Roast Beef Sandwich: Make It at Home

An Arby’s-style roast beef sandwich pairs thinly sliced, tender roast beef with a soft sesame bun and a little tangy barbecue sauce. This simple copycat version warms deli roast beef gently so it stays juicy, then builds the sandwich just before serving.

Ingredients

1 pound (454 g) thinly sliced deli roast beef
4 sesame hamburger buns, about 2 ounces (57 g) each
1 cup (240 ml) low-sodium beef broth
2 tablespoons (30 ml) water, if needed to thin the broth
½ cup (120 ml) prepared barbecue sauce, plus more to serve
1 tablespoon (15 ml) ketchup
1 teaspoon (5 ml) apple cider vinegar
¼ teaspoon garlic powder (about 1 g)
⅛ teaspoon freshly ground black pepper (about 0.3 g)
1 tablespoon (14 g) unsalted butter, optional, for toasting the buns

Instructions

Make the sauce. In a small bowl, stir together the barbecue sauce, ketchup, apple cider vinegar, and garlic powder. Set aside. If your barbecue sauce is already tangy, start with ½ teaspoon of vinegar and add more to taste.
Warm the broth. Pour the beef broth into a wide skillet and add the black pepper. Bring it to a gentle simmer over medium heat; do not let it boil hard. If the broth is very concentrated or salty, add up to 2 tablespoons of water.
Heat the roast beef gently. Separate the slices and add them to the simmering broth in loose handfuls. Turn and separate the meat with tongs for about 2–3 minutes, just until steaming hot. For food safety, USDA FSIS recommends reheating leftovers to 165°F (74°C); if using previously cooked roast beef, check the thickest folded portion with a food thermometer and reach that temperature. Avoid prolonged heating, which can make thin slices tough. Lift the meat out with tongs and let excess broth drip back into the skillet.
Toast the buns (optional). Melt the butter in a separate skillet over medium heat. Place the cut sides of the buns in the pan and toast for 1–2 minutes, until lightly golden. Alternatively, serve them untoasted for a softer sandwich.
Assemble and serve. Divide the hot beef among the bottom buns, folding the slices loosely rather than compressing them. Spoon about 1–2 tablespoons of sauce over each portion, add the top buns, and serve immediately with extra sauce on the side.

Tips

Choose the right cut. Ask for thin-sliced deli roast beef, ideally sliced on the thinner side. Rare, medium, and well-done deli styles all work; the final texture will differ, so warm each just until hot.
Keep the broth at a gentle simmer. A rolling boil can break delicate slices apart and make them chewy. If the beef is already hot, remove it from the skillet rather than leaving it in the broth.
Adjust the sauce to your taste. A smoky barbecue sauce makes the closest easy match. If you do not have one, use a mild barbecue sauce and add a little extra vinegar for tang; avoid adding much salt before tasting.
Use a thermometer when reheating. Folded slices can warm unevenly. Check a thick portion rather than relying only on steam or appearance, and do not leave cooked beef sitting at room temperature for more than 2 hours.

Serving Suggestions

Serve the sandwiches as soon as they are assembled, while the beef is hot and the buns are still soft. Crinkle-cut fries, potato wedges, coleslaw, or a crisp green salad make easy sides. For a more casual spread, set out pickles, extra barbecue sauce, and sliced onions so everyone can customize a sandwich.

Keep any dipping broth separate from the barbecue sauce: the broth is savory and beefy, while the sauce is sweet and tangy. If you would like a juicier sandwich, spoon a teaspoon or two of the warm broth over the beef before adding sauce, but avoid soaking the bun.

Variations

Cheese version: Add a slice of provolone or cheddar to each sandwich and briefly cover the skillet or warm the assembled sandwich until the cheese melts. Keep the beef covered only long enough to melt the cheese.
Onion version: Cook 1 cup (150 g) thinly sliced onion in a little oil until soft and lightly browned, about 8–10 minutes, then add it on top of the beef.
Spicy version: Stir ¼ teaspoon (about 1 g) cayenne or a few dashes of hot sauce into the barbecue sauce. Start small and taste before adding more.
Simple beef-and-bun version: Skip the barbecue sauce and serve the warm beef with a little prepared horseradish or mustard. These change the flavor from sweet and smoky to sharper and more savory.

Storage and Reheating

For the best texture, store the roast beef, sauce, and buns separately. Refrigerate the beef and sauce within 2 hours of serving in covered containers; cooked roast beef and prepared sauce keep for 3–4 days in the refrigerator at 40°F (4°C) or below. Follow the package date and storage instructions for deli meat, and discard it if it has been left out longer than 2 hours (1 hour when the temperature is above 90°F/32°C). Buns are best kept at room temperature in a closed bag and used according to their package directions.

Reheat only the amount of beef you plan to eat. Warm it in a skillet with a splash of broth over medium-low heat, stirring gently, until it reaches 165°F (74°C) as checked with a food thermometer. You can also microwave it covered in short intervals, stirring between intervals and checking the temperature in more than one spot. Reheat sauce separately until hot, then assemble the sandwiches. Avoid repeatedly cooling and reheating the same portion.

Frequently Asked Questions

Can I use leftover homemade roast beef?
Yes. Slice it as thinly as possible and warm it gently in the broth. Since it is already cooked, the goal is to heat it through without simmering it long enough to dry out; if reheating leftovers, bring them to 165°F (74°C).

Can I make the sandwiches ahead?
You can prepare the sauce ahead and refrigerate it, and you can portion the beef in advance. Warm the beef and toast the buns just before serving. Assembled sandwiches soften quickly, so they are better made at the last minute.

What can I use instead of beef broth?
Use low-sodium beef stock, or water with a small amount of beef bouillon prepared according to its label. Chicken broth will work in a pinch, but it gives the beef a less pronounced, slightly different flavor.

Do I need to add salt?
Usually not at first. Deli roast beef, broth, and bottled barbecue sauce can all contain plenty of salt. Taste the warmed beef and sauce before seasoning, and choose low-sodium broth if you want more control.

How do I keep the bun from getting soggy?
Drain the beef well after warming, toast the cut sides of the buns, and add sauce just before eating. Serve extra sauce on the side rather than pouring broth over the finished sandwich.

Can I freeze the leftovers?
Freezing is possible, though the beef may lose some tenderness after thawing. Freeze the beef and sauce separately in airtight freezer-safe containers for up to 2–3 months for best quality. Thaw in the refrigerator, then reheat the beef to 165°F (74°C); do not freeze assembled sandwiches.

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Safety notes: safe minimum internal temperatures from USDA FSIS; raw and undercooked fish guidance from the U.S. FDA. Food safety notes

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