This is a homemade take on Carl’s Jr.’s Double Western Bacon Cheeseburger — two beef patties, sharp cheddar, thick-cut bacon, onion rings, and barbecue sauce on a toasted sesame bun. The real reason to make it at home is control: better beef, crispier bacon, and onion rings that actually hold their crunch instead of arriving soggy from a heat lamp.
Shopping notes
- Ground beef: Go with 80/20. Leaner blends dry out fast under high heat, and this burger needs that fat to stay juicy through a double stack.
- Bacon: Thick-cut matters here. Standard thin-cut bacon cooks down to almost nothing and gets lost between two patties. Applewood- or hickory-smoked both work well.
- Onion rings: Frozen beer-battered rings (store-bought) are a completely reasonable shortcut and hold up better in the stack than homemade rings, which tend to steam and soften quickly. If you’re making them from scratch, fry them right before assembly.
- Barbecue sauce: Use one with some molasses depth — thin, vinegar-forward sauces disappear into the other flavors. A smoky-sweet bottle sauce works fine; save the chipotle version for when you want noticeable heat.
- Buns: Sesame seed buns are standard. Brioche buns are softer and will compress under the weight of a double stack, so toast them firmly.
What makes this version work
Two things actually move the needle on this burger. First, getting a hard sear on both patties — cast iron or a very hot stainless pan beats a nonstick here because you need real browning, not steaming. Press the patties flat before they hit the pan and don’t move them for the first 2–3 minutes; that crust is where most of the flavor lives. Second, the assembly order matters: sauce goes on the bun first, then the bottom patty with cheese, then bacon, then the second patty with cheese, then the onion rings, then more sauce on the top bun. Putting the onion rings above the second patty keeps them away from direct moisture longer, which means they stay crunchier through the first half of the burger. Skip adding any binder to the patties — breadcrumbs or egg in the mix make the texture soft and loose rather than giving you that firm, sliceable bite the original has.
Common problems and fixes
- Patties puff up in the middle: Press a small indent into the center of each raw patty with your thumb before cooking. The patty will cook flat instead of doming, which means more even contact with the pan and more consistent doneness throughout.
- Cheese won’t melt properly: Add the cheese slice in the last 60 seconds of cooking and cover the pan with a lid or a metal bowl. The trapped steam melts the cheese without overcooking the patty.
- Bacon stays chewy instead of crispy: Start bacon in a cold pan, then bring the heat up gradually. This renders the fat slowly and gives you even crispness. Draining on a wire rack instead of paper towels also keeps it from steaming itself soft.
- Burger falls apart when you pick it up: Let the assembled burger sit for 60–90 seconds before serving. The cheese firms slightly and the sauce settles, which helps everything hold together as a stack.
- Bun gets soggy fast: Toast the cut sides of the bun in the same pan after the patties come off — 30–45 seconds on medium heat. A toasted surface resists sauce absorption much better than a lightly warmed bun.
Storage and reheating
Cooked patties keep in the fridge for up to 3 days in an airtight container. Bacon stores separately for the same window. Don’t store assembled burgers — the bun turns to mush overnight. To reheat patties, use a covered skillet over medium-low heat with a splash of water to create steam; this warms them through without drying out the exterior. Aim for an internal temperature of 160°F (71°C) when reheating ground beef. Cooked patties can be frozen for up to 2 months — wrap individually in plastic wrap, then foil. Thaw overnight in the fridge before reheating. Reheat frozen onion rings in an oven or air fryer at 400°F for 5–7 minutes to get the crunch back; microwaving them produces a soft, sad result.
Double Western Bacon Cheeseburger (Carl’s Jr. Copycat)
Ingredients
- 1 lb ground beef (80/20) for juicier, more flavorful patties
- ½ tsp kosher salt to season patties
- ½ tsp freshly ground black pepper
- 4 slices thick-cut bacon smoked preferred for authenticity
- 4 slices cheddar cheese preferably sharp and thick-sliced
- ¼ cup barbecue sauce use a smoky, slightly sweet variety
- 4 pieces frozen onion rings or homemade; bake or fry per package directions
- 2 pieces sesame seed burger buns toasted for a better bite
Instructions
- Prepare the Onion Rings: Bake or fry the onion rings according to package instructions (usually 15–20 minutes at 425°F / 220°C for baking). They should be golden, crispy, and hold their shape well.
- Cook the Bacon: In a skillet over medium heat, fry the bacon until crisp and browned (about 6–8 minutes). Drain on paper towels.
- Shape and Season Burger Patties: Divide ground beef into 4 equal portions and gently form into 4-inch wide patties (don’t overwork the meat). Season both sides with kosher salt and pepper.
- Cook the Burger Patties: Heat a skillet or grill pan over medium-high heat. Cook patties for 3–4 minutes per side or until nicely browned and cooked through. Add a slice of cheese to each patty in the last minute of cooking, covering with a lid to melt the cheese.
- Toast the Buns: While the burgers cook, toast the sesame buns cut-side down on a hot skillet or under the broiler for 1–2 minutes until golden and crisp.
- Assemble the Burgers: On the bottom bun, drizzle barbecue sauce, then place one cheese-covered patty, a slice of bacon, an onion ring, followed by the second patty and another slice of bacon and onion ring. Add more sauce and close with the top bun.
Notes
- For a spicier edge, try a chipotle BBQ sauce or add jalapeños between the layers.
- You can swap beef with ground turkey for a lighter version, though cook time may vary slightly.
- If you have time, make your own beer-battered onion rings for extra crunch and artisanal flair.
Nutrition
Common questions
Can I cook the patties on a grill instead of a pan?
Yes, a charcoal or gas grill works well for this recipe. Cook over direct medium-high heat and use a meat thermometer to confirm the internal temperature reaches 160°F (71°C) — ground beef should never be served pink. The grill adds a light smokiness that complements the barbecue sauce.
What’s the best way to keep the onion rings crispy in the burger?
Cook or heat the onion rings last, right before assembly, and place them on top of the second patty rather than underneath it. Direct contact with hot meat and sauce is what kills the crunch, so keeping them near the top bun buys you more time.
Can I make the patties ahead of time?
You can form and season the raw patties up to 24 hours ahead — stack them with parchment between each one and refrigerate uncovered for the first 30 minutes so the surface dries slightly, which helps with searing. Cook them straight from the fridge; cold patties hold their shape better in a hot pan.
Is there a swap for the sesame seed bun?
A potato roll or a standard soft hamburger bun both work, but make sure to toast whichever bun you use — it’s the main thing keeping the bottom from going soggy under two sauced patties. Avoid anything too thick or crusty, which makes the burger hard to bite through cleanly.
If you liked this one
- Beyond Western Bacon Cheeseburger
- Carl’s Jr. Philly Cheesesteak Burger
- Perfect Bacon Double Cheeseburger
- BBQ Cheeseburger Recipe