Ingredients:

  • 5 lbs (680 g) Ground Beef (85/15 ratio preferred)
  • 1 large Yellow Onion, finely diced
  • 3 cloves Garlic, minced
  • 1 Tbsp Olive Oil
  • 2 Tbsp Tomato Paste
  • ¾ cup Ketchup (180 ml)
  • 2 Tbsp Apple Cider Vinegar (30 ml)
  • 2 Tbsp Brown Sugar (packed)
  • 1 Tbsp Worcestershire Sauce
  • 1 tsp Yellow Mustard
  • ½ cup Water or Beef Stock (120 ml)
  • 1 tsp Smoked Paprika
  • ½ tsp Chili Powder
  • ¼ tsp Cayenne Pepper (optional)
  • 1 tsp Kosher Salt, or to taste
  • ½ tsp Black Pepper, freshly ground
  • 1 cup Sharp Cheddar Cheese, freshly grated, divided
  • ½ cup Monterey Jack or Mozzarella, freshly grated
  • 6 Brioche Buns or Potato Rolls, lightly toasted
  • Butter or Oil, as needed for toasting buns

Instructions:

  1. Prep the Aromatics: Finely dice the onion and mince the garlic.
  2. Brown the Beef: Heat the large skillet or Dutch oven over medium-high heat. Add the ground beef and season lightly with salt and pepper. Break up the meat and cook until fully browned (about 6-8 minutes).
  3. Drain the Fat: Carefully drain off all excess grease from the skillet. This is crucial for texture. Return the beef to the pan.
  4. Sauté the Base: Reduce heat to medium. Push the beef to one side, add the olive oil, and then the diced onion. Cook until the onion is translucent (about 4 minutes).
  5. Toast the Tomato Paste: Stir the tomato paste and minced garlic into the onions and beef mixture. Cook for 1 minute, stirring constantly, until the paste darkens slightly to deepen the tomato flavor.
  6. Add the Liquids and Seasoning: Pour in the ketchup, water/stock, brown sugar, apple cider vinegar, Worcestershire sauce, and yellow mustard. Stir to combine thoroughly. Add the smoked paprika, chili powder, and cayenne (if using). Stir well.
  7. Simmer: Bring the mixture to a gentle simmer. Reduce the heat to low, cover the skillet partially, and let the sauce cook for 10–15 minutes, stirring occasionally. The sauce is ready when it thickens and clings tightly to the meat with no standing liquid.
  8. Stir in the Cheese: Remove the skillet from the heat. Stir in 1 cup of the grated sharp cheddar and Monterey Jack blend until completely melted and incorporated into the filling. Taste and adjust seasoning (salt, pepper, or a pinch more vinegar/sugar).
  9. Toast the Buns: Slice the rolls open. Lightly butter or brush the cut sides with oil. Toast face-down in a separate, clean skillet or under the grill (broiler) for 1–2 minutes until golden brown and crisp.
  10. Serve: Spoon a generous amount of the cheesy BBQ filling onto the bottom half of the toasted bun. Top with the remaining bun half and serve immediately.