Arby's-Style Roast Beef Sandwiches & Curly Fry Dupes You Can Make at Home

# Arby's-Style Roast Beef Sandwiches & Curly Fry Dupes You Can Make at Home

There's a very specific craving that hits you around 2 PM on a Saturday — one that can only be described as thin-sliced, saucy, piled-high roast beef on a toasted sesame bun with a fistful of aggressively seasoned curly fries on the side. You know the one. It's the Arby's craving. And while the drive-through is always an option, what if I told you that you could recreate that exact experience at home — often using things already sitting in your fridge and pantry — and make it taste even better?

This recipe is a love letter to that iconic fast food combo. We're talking tender, paper-thin sliced roast beef with a savory, slightly smoky au jus–style sauce, piled onto a soft toasted bun and finished with a tangy Arby's-style horseradish cheddar sauce. And on the side? Homemade curly fries seasoned with that unmistakable blend of paprika, onion, garlic, and cumin that makes you involuntarily close your eyes after the first bite. The best part? No special equipment required beyond what's likely already in your kitchen.

Whether you're cooking for a hungry family on a Sunday afternoon, hosting a game-day crowd, or just treating yourself because you deserve it, this recipe delivers every bit of that fast-food satisfaction with a homemade touch that takes the whole thing to another level. Let's get into it.

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Ingredients

For the Roast Beef

• 2–2.5 lbs eye of round roast — This is the closest cut to what Arby's uses. It's lean, slices beautifully thin, and stays tender when cooked low and slow. Chuck roast works too for a fattier, richer result.
• 1 tbsp olive oil
• 1 tsp garlic powder
• 1 tsp onion powder
• 1 tsp smoked paprika
• 1 tsp kosher salt
• ½ tsp black pepper
• ½ tsp dried thyme

For the Au Jus–Style Dipping Sauce

• 2 cups beef broth (low sodium preferred so you control saltiness)
• 1 tbsp Worcestershire sauce
• ½ tsp garlic powder
• ½ tsp onion powder
• Salt and pepper to taste

For the Arby's-Style Cheddar Horseradish Sauce

• ½ cup mayonnaise
• 2 tbsp prepared horseradish (adjust to your heat preference)
• ¼ cup sour cream
• ½ cup shredded sharp cheddar cheese, melted and cooled slightly
• 1 tsp Dijon mustard
• 1 tsp apple cider vinegar
• Salt to taste

For the Sandwiches

• 4–6 sesame seed hamburger buns (brioche buns work beautifully here)
• Butter for toasting

For the Curly Fries

• 4 medium russet potatoes — The starch content in russets gives you that crispy exterior. Yukon golds work in a pinch but won't curl quite the same way.
• 3 tbsp olive oil or vegetable oil
• 1½ tsp smoked paprika
• 1 tsp garlic powder
• 1 tsp onion powder
• ½ tsp cumin
• ½ tsp cayenne pepper (reduce if you're spice-averse)
• ½ tsp turmeric — This is the secret to that Arby's golden-orange color
• 1 tsp kosher salt
• ½ tsp black pepper
• 1 tbsp cornstarch — Helps achieve that signature crunch

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Instructions

Make the Roast Beef

1. Preheat your oven to 225°F (low and slow is the key). Pat the eye of round roast completely dry with paper towels — this is essential for a good sear. Moisture is the enemy of a beautiful crust.

1. Mix the spice rub in a small bowl: garlic powder, onion powder, smoked paprika, salt, pepper, and thyme. Rub the entire roast generously with olive oil, then press the spice mixture all over every surface. Don't rush this — you want full coverage.

1. Sear the roast in an oven-safe skillet or Dutch oven over medium-high heat. Add a drizzle of oil and sear each side for 2–3 minutes until a deep, mahogany crust forms and you smell that intoxicating caramelized beef aroma. This step adds enormous flavor — don't skip it.

1. Transfer the skillet to the oven and roast at 225°F for approximately 2.5–3 hours, or until an instant-read thermometer reads 130–135°F for medium-rare (which produces the most tender, juicy slices). For medium, pull at 140°F. Remember: Arby's beef is pink in the middle — that's intentional and where the magic lives.

1. Rest the roast on a cutting board, loosely tented with foil, for at least 20 minutes before slicing. This is non-negotiable. Cutting too early sends all those precious juices running onto the board instead of staying in the meat.

1. Slice as thin as humanly possible — use the sharpest knife you own, or better yet, a meat slicer if you have one. The thinner, the better. Pile slices loosely so they stay pillowy and don't compress into a dense brick.

Make the Au Jus

1. While the roast rests, combine beef broth, Worcestershire sauce, garlic powder, and onion powder in a small saucepan over medium heat. Bring to a gentle simmer and let it reduce for about 10 minutes until it deepens in color and flavor. Taste and adjust salt and pepper. Keep warm on low heat until ready to serve.

Make the Cheddar Horseradish Sauce

1. Melt the shredded cheddar in a small bowl in the microwave in 20-second bursts, stirring between each, until just melted and smooth. Let it cool for a couple of minutes so it doesn't break the mayo.

1. Whisk together the mayo, sour cream, horseradish, Dijon, and apple cider vinegar. Fold in the cooled melted cheddar until fully combined. Taste it — it should be tangy, creamy, mildly spicy, and slightly sharp. Add salt as needed. Refrigerate until ready to use.

Make the Curly Fries

1. Preheat your oven to 425°F and line two large baking sheets with parchment paper. If using an air fryer, preheat to 400°F.

1. Spiralize the potatoes using a spiralizer on the medium-thickness setting. If going freehand, use a vegetable peeler for long ribbons or a crinkle cutter for wavy strips. Place the cut potatoes in a large bowl of cold water and soak for 20 minutes — this removes excess starch and dramatically improves crispiness.

1. Drain and dry the potatoes thoroughly using clean kitchen towels or paper towels. Spread them on a clean towel and pat aggressively. Wet fries steam instead of crisp — don't let this happen to you.

1. Toss the dried potatoes in olive oil in a large bowl. In a small bowl, mix together the smoked paprika, garlic powder, onion powder, cumin, cayenne, turmeric, salt, pepper, and cornstarch. Sprinkle the seasoning mixture over the oiled potatoes and toss until every curl is evenly coated and orange-golden.

1. Spread in a single layer on baking sheets, giving each fry room to breathe. Overlapping fries = soggy fries. Roast at 425°F for 25–30 minutes, flipping once halfway through, until golden, crispy, and deeply fragrant with that signature warm-spice aroma. For air fryer: cook in batches at 400°F for 15–18 minutes, shaking the basket halfway.

Assemble the Sandwiches

1. Butter and toast the buns cut-side down in a skillet over medium heat until golden and slightly crispy — about 2 minutes. This tiny step makes a huge difference in texture and prevents a soggy bottom.

1. Spread a generous amount of cheddar horseradish sauce on both halves of the bun. Pile on as much roast beef as your conscience allows — don't be shy. Drizzle a little warm au jus directly onto the beef before closing the sandwich for extra juicy flavor.

1. Serve immediately alongside the curly fries with extra au jus for dipping.

Tips & Variations

Use a meat slicer or ask your butcher. If you have access to a meat slicer, use it — Arby's signature texture comes entirely from those paper-thin slices. Alternatively, ask your local butcher to slice the cooked roast for you, or freeze the roast for 20–30 minutes before slicing to firm it up for thinner cuts.

Deli roast beef shortcut. Short on time? Use high-quality deli-sliced roast beef from the grocery store (Boar's Head is excellent). Heat the slices gently in the warm au jus for 2–3 minutes before building your sandwich. It's not quite the same, but it's a legitimately great weeknight hack.

Spice the fries to your preference. The curly fry seasoning blend is endlessly customizable. Add a pinch of brown sugar for a subtle sweetness, swap cayenne for chili powder for a milder heat, or add a little dried oregano for an earthier edge.

Make it a Beef 'n Cheddar. Arby's famous Beef 'n Cheddar uses a bright orange cheddar pump sauce and a onion roll. Swap the sesame bun for an onion roll, skip the horseradish, and thin the cheddar sauce slightly with a little cream for a pourable consistency.

Go slow cooker. For an even more hands-off approach, rub and sear the roast the same way, then transfer to a slow cooker with ½ cup beef broth and cook on LOW for 6–8 hours. The meat will be falling-apart tender and slice (or pull) beautifully.

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Storage & Reheating

Roast Beef: Store sliced beef in an airtight container submerged in or alongside the au jus in the refrigerator for up to 4 days. The jus keeps the meat moist and prevents it from drying out. To reheat, warm gently in a saucepan with the au jus over low heat — never microwave dry or you'll get rubbery, sad beef.

Cheddar Horseradish Sauce: Keeps refrigerated for up to 5 days in a sealed jar. Stir before each use. It actually gets better after the first day as the flavors meld.

Curly Fries: These are best fresh, but you can store leftovers in an airtight container in the fridge for up to 3 days. Reheat in a 400°F oven or air fryer for 8–10 minutes to restore crispiness. Avoid the microwave — it makes them limp and sad.

Freezer-Friendly: The unsliced roast freezes exceptionally well. Wrap tightly in plastic wrap and then foil, freeze for up to 3 months, and thaw overnight in the refrigerator before slicing and serving.

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Nutrition Notes

Eye of round is one of the leanest cuts of beef available, making this a significantly leaner sandwich than many fast-food alternatives. The homemade au jus lets you control sodium levels, which can be dramatically lower than restaurant versions. Baking the curly fries instead of deep-frying them slashes the fat content considerably while still delivering that satisfying crunch. The cheddar horseradish sauce adds richness, but a little goes a long way — even a modest spread delivers full flavor. Overall, this is comfort food made with real, whole ingredients — and that matters.

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FAQ

Can I use a different cut of beef? Absolutely. Eye of round is ideal for its lean, uniform shape and Arby's-like texture, but top round, bottom round, and even sirloin tip roast all work well. Chuck roast will give you a fattier, more pot-roast-style result — still delicious, just a different vibe. Whatever you use, low-and-slow cooking and proper resting time are the real keys to success.

I don't have a spiralizer. Can I still make curly fries? Yes! A spiralizer helps achieve that iconic curl, but you have options. A vegetable peeler can create long, thin potato ribbons. A crinkle cutter creates wavy strips that mimic the texture beautifully. Even regular thin-cut fries seasoned with this spice blend will taste spot-on — the seasoning is where most of the Arby's magic comes from anyway.

How do I get the beef sliced thin enough without a slicer? The trick is temperature — a slightly chilled roast slices much more cleanly than a warm one. After resting, pop the roast in the freezer for 15–20 minutes (not long enough to freeze it, just to firm it up), then use the sharpest, longest knife you own and apply steady, even pressure with long strokes rather than sawing. Patience wins here.

Can I make this ahead for a party? This recipe is actually perfect for entertaining. Roast the beef the day before, refrigerate overnight in the au jus, and slice cold (it's actually easier to slice cold). Make the cheddar sauce up to two days ahead. On the day of the party, gently rewarm the beef and au jus in a slow cooker on WARM or LOW, set out the sauce, and let guests build their own sandwiches. The fries are best made fresh, but you can prep and season the raw spiralized potatoes up to 4 hours ahead — just keep them in cold water until ready to cook.