This is a copycat of the Burger King Bacon Double XL — two quarter-pound beef patties, American cheese, and crispy bacon on a sesame bun, cooked over direct flame or high broiler heat to get that charred, smoky crust. It’s worth making at home because you control the beef quality and the bacon-to-burger ratio, and you can actually eat it hot instead of out of a paper bag.
What makes this version work
Two things matter here. First, heat — real, aggressive heat. The char on a flame-broiled burger isn’t decoration; it’s where most of the flavor lives. A screaming-hot grill grate or a cast-iron pan pushed as high as it goes will get you there. A medium flame won’t. Second, fat content in the beef: 80/20 ground chuck is the right call. Leaner beef dries out fast under that kind of heat, and you’re cooking two patties stacked, so there’s no margin for dry meat. Get the fat right and the juiciness takes care of itself.
Smart swaps
- American cheese: This is one place where the processed stuff is actually correct — it melts flat and fast across a hot patty. Cheddar works but won’t melt as evenly; give it an extra 30 seconds under a lid with a splash of water in the pan.
- Sesame seed bun: A brioche bun holds up better under two patties and all that juice. Potato rolls are a solid backup if that’s what you have.
- Bacon: Thick-cut bacon looks impressive but can be chewy in a burger stack. Regular-cut crisps up faster and stays put when you bite through. Skip thick-cut here — it fights the patties instead of complementing them.
- No outdoor grill: A cast-iron skillet or grill pan on the highest burner setting is the practical indoor option. A broiler set to high with the rack close to the element also works.
Make-ahead notes
Formed raw patties can be stacked between parchment sheets and refrigerated for up to 24 hours — any longer and the edges start to oxidize and the texture suffers. For longer storage, freeze them on a sheet pan until solid, then transfer to a zip bag; they’ll keep for up to 2 months. Cook from frozen by adding 3-4 minutes per side and confirming 160°F (71°C) internal with a thermometer. Cooked bacon can be crisped ahead and kept in a sealed container at room temperature for up to 8 hours — re-crisping it in a dry pan for 60 seconds before building the burger is all it needs. Assembled burgers don’t hold well; build them right before serving.
If something goes sideways
- Patties are puffing up in the middle: Press a shallow thumbprint into the center of each raw patty before cooking. The patty will cook flat instead of doming up and squeezing out the toppings.
- Bottom bun is soggy before you even sit down: Toast the cut side of both bun halves in the same pan after the bacon comes out — 60 seconds on medium heat. The toasted surface resists juice absorption long enough to actually eat the burger.
- Cheese isn’t melting before the beef overcooks: Lay the cheese on the patty, add a teaspoon of water to the pan, and immediately cover with a lid or a large metal bowl. The steam melts the cheese in about 30 seconds without pushing the beef past 160°F.
- Bacon keeps sliding out with every bite: Lay the bacon strips crosswise across the patty rather than lengthwise. They anchor better and you get bacon in every bite instead of pulling the whole strip out on the first one.
- Two-patty stack is too tall to eat: Press the assembled burger down firmly with your palm before the first bite — not hard enough to squeeze everything out, just enough to compress the bun into the stack. It holds together much better.
Chef’s Bacon Double XL—Flame-Kissed Copycat
Ingredients
For the Bacon & Aromatics:
- 8 slices thick-cut smoked bacon applewood-smoked preferred for deeper sweetness
- 0.5 cup white onion, finely diced about 1 small onion; use fresh for crisp bite
- 8 chips dill pickles well-drained; chilled for crunch
For the Beef Patties:
- 1 lb 80/20 ground chuck cold; coarse grind if possible for better texture
- 1 tsp kosher salt Diamond Crystal preferred; adjust if using fine salt
- 0.5 tsp freshly ground black pepper medium grind for gentle heat
- 1 tsp Worcestershire sauce optional, for umami depth without masking beef
- 0.5 tsp garlic powder optional; keeps flavor savory but clean
For the Buns & Cheese:
- 2 whole sesame seed burger buns sturdy, soft; 4 to 5-inch buns hold the double stack well
- 2 tbsp unsalted butter, softened for toasting buns; ghee works for higher heat
- 4 slices American cheese good deli American melts best; cheddar works if preferred
For the House Sauce:
- 2 tbsp ketchup choose a balanced, not overly sweet brand
- 2 tbsp mayonnaise full-fat for best texture and shine
- 1 tsp yellow mustard classic tang; Dijon if you prefer sharper bite
For Cooking:
- 1 tbsp neutral oil canola or avocado oil for pan or griddle, if not grilling
Instructions
- Chill and Portion the Beef (5 minutes): Keep the ground chuck cold for better sear and juiciness. Divide into 4 portions (about 4 oz each). Gently form loose 3.5 to 4-inch patties with minimal handling; press a shallow dimple in the center of each to prevent doming.
- Crisp the Bacon (8–10 minutes): Place bacon in a cold skillet and set over medium heat. Cook, flipping occasionally, until deeply golden and crisp, 8–10 minutes. Transfer to a rack or paper towel. Reserve 1 teaspoon bacon fat for optional onion sauté.
- Mix the House Sauce (2 minutes): In a small bowl, stir together ketchup, mayonnaise, and yellow mustard until smooth. Taste and balance: a pinch of salt or a drop of Worcestershire can round it out if desired.
- Preheat Your Cooking Surface (5–10 minutes): For authentic char, preheat a gas or charcoal grill to high, about 500–550°F (260–290°C). Alternatively, heat a cast-iron skillet or griddle over medium-high for 3–4 minutes, adding 1 tbsp neutral oil just before searing.
- Season and Cook the Patties (6–8 minutes): Season each patty with kosher salt and black pepper on both sides; brush lightly with Worcestershire and dust with garlic powder if using. Cook 2–3 minutes per side on a ripping-hot grill or skillet until well-browned with a hint of char. Target an internal temp of 145°F (63°C) for medium; adjust to your preference, always minding food safety. In the last 30–45 seconds, drape 1 slice of American cheese over two of the patties and 1 slice over the other two to melt.Alternative: For a broiler method, place patties on a wire rack over a foil-lined sheet and broil on high (about 500–550°F / 260–290°C) 3–4 minutes per side; finish with cheese under the broiler for 10–20 seconds.
- Toast the Buns (1–2 minutes): Split buns, spread cut sides with softened butter, and toast cut-side down on the grill or skillet until golden at the edges and fragrant, 1–2 minutes. Aim for light crunch and soft interior.
- Onions (optional warm-up, 1 minute): For a softer bite, briefly warm the diced onions in 1 tsp reserved bacon fat over medium heat for 30–60 seconds—just until glossy, not browned. Or keep them raw for bright crunch. Pat pickles dry so they don’t sog the bun.
Assembly:
- Spread 1 to 2 teaspoons house sauce on each bottom bun.
- Add a layer of pickle chips and a scattering of diced onion.
- Set down the first cheesy patty, then 2 crisp bacon slices.
- Top with the second cheesy patty and another 2 slices of bacon.
- Swipe the top bun with more house sauce and cap the burger.
- Rest (1 minute): Let the burger sit for 30–60 seconds so juices settle and the cheese fully hugs the patties.
Notes
Chef’s Tips:
- Beef Blend: 80/20 chuck is classic; a 50/30/20 chuck/brisket/short rib mix is luxurious.
- Flame-Kissed Aroma: On a skillet, add a tiny drop of liquid smoke to the pan oil or brush patties with a light mix of oil and smoked paprika.
- Crispier Bacon: Start bacon in a cold pan and add 2 tbsp water; it renders gently and reduces splatter as it crisps.
- Melt Control: Cover the pan for 10–15 seconds after adding cheese to trap steam and achieve that photo-worthy drape.
- Dietary Swaps: Use turkey bacon and a plant-based patty; gluten-free sesame buns work beautifully. Dairy-free? Try a meltable vegan American-style slice.
- Seasoning Restraint: Keep spices subtle so beef and smoke lead; the sauce provides the tang.
- Keep meat cold and your cooking surface hot for best browning.
- If using fine salt, reduce by about 25% compared to kosher.
- Food Safety: USDA recommends 160°F (71°C) for ground beef; cook to your preference with informed care.
Nutrition
Frequently asked questions
Can I use a flat-top griddle instead of a grill?
Yes, but you’ll get a different crust — more Maillard browning, less char. Crank the griddle as hot as it goes and don’t move the patties for the first 2-3 minutes so a proper sear develops rather than a gray steam-cooked surface.
How do I know when the patties are actually done without cutting them open?
Use an instant-read thermometer and pull the patties at 160°F (71°C) — that’s the safe temperature for ground beef. Insert it horizontally through the side of the patty into the center for an accurate read.
Can I make this with a leaner ground beef to cut the fat?
You can, but 90/10 or leaner will give you a noticeably drier, tougher patty under high heat. If you want to go leaner, add a tablespoon of mayonnaise mixed into the beef before forming — it adds back enough fat to keep the texture reasonable.