This is a homemade double cheeseburger built to match the Carl’s Jr. Super Star — two thin beef patties, American cheese, lettuce, tomato, pickles, onion, ketchup, and mayo on a sesame seed bun. The honest reason to make it at home: fresh 80/20 beef and deli-counter cheese taste noticeably better than the drive-thru version, and the whole thing takes about 45 minutes. No special equipment needed beyond a skillet.
The short version of why this works
Two things make or break this burger. First, thin patties cooked in a very hot cast iron pan. That high heat creates a browned, slightly crispy crust on the outside while keeping the inside juicy — you don’t get that from a lukewarm pan. Second, toasting the cut sides of the bun. It takes 60 seconds and it’s the difference between a bun that holds up and one that turns soggy before you finish eating. Everything else is just assembly.
Common problems and fixes
- Patties shrink into thick pucks: This happens when the beef is packed too tight or the patties are too thick to begin with. Press them thinner than you think you need — they’ll shrink as they cook. Loose, gentle shaping is all you need.
- Cheese won’t melt: Add the cheese slice right after you flip the patty, then cover the pan with a lid or a sheet of foil for 30–45 seconds. Trapped steam does the work fast.
- Burger falls apart when you pick it up: This usually means the toppings are stacked in the wrong order. Keep the cold, slippery items (tomato, onion) between the two patties rather than on the outside edges where they can slide.
- Bun gets soggy fast: Spread the mayo on the bun before any wet toppings go on. The fat in the mayo acts as a barrier. Pickles and lettuce directly on the mayo side also help.
- Patties stick to the pan: Don’t move them for the first 2 minutes. A properly seared patty releases on its own when it’s ready to flip. Forcing it early tears the crust and causes sticking.
Substitutions that actually work
- 80/20 ground beef: This fat ratio is important — leaner beef (90/10 or higher) will give you a dry, crumbly patty. Stick with 80/20 if you can.
- American cheese: Skip the individually wrapped processed slices if possible. Deli-sliced American melts cleaner and tastes more like actual cheese. Skip adding shredded cheddar as a swap — it doesn’t melt evenly on a thin patty.
- Sesame seed bun: A brioche-style sesame bun works well here and adds a slight richness. Avoid anything too thick or crusty — it overpowers the thin patties.
- Yellow onion: White onion is a fine substitute. Red onion works but is sharper; soak slices in cold water for 10 minutes to mellow them out if that’s what you have.
- Dill pickle slices: Bread-and-butter pickles are sweeter and change the flavor profile noticeably. Dill is the right call here.
Storage and reheating
Cooked patties keep in the fridge for up to 3 days in an airtight container. Reheat them in a covered skillet over medium-low heat for 2–3 minutes per side — this keeps them from drying out the way a microwave does. For freezing, wrap raw shaped patties individually in plastic wrap and freeze for up to 2 months; thaw overnight in the fridge before cooking. Don’t freeze assembled burgers — the vegetables and bun don’t survive it. Build fresh every time.
Carl’s Jr. Super Star with Cheese - Gourmet Copycat Version
Ingredients
For the Burger Patties:
- 1 lb 80/20 ground beef chuck fresh if possible, not frozen
- ½ tsp kosher salt to season the meat
- ¼ tsp freshly ground black pepper
For the Burger Assembly:
- 4 slices American cheese use quality deli-style for best melt
- 2 pieces sesame seed hamburger buns preferably brioche-style for a slightly sweet touch
- 2 large green leaf lettuce leaves
- 4 medium tomato slices firm, ripe tomatoes like vine-ripened or beefsteak
- 4 pieces dill pickle slices preferably crinkle-cut for extra crunch
- ½ small yellow onion sliced into thin rings
- 2 tbsp ketchup
- 2 tbsp mayonnaise
Instructions
- Prepare the Burger Patties: Divide the ground beef into 4 equal portions (about 4 oz each). Form into thin, slightly larger than bun-sized patties — they’ll shrink during cooking. Avoid overworking the meat, and optionally press a shallow dimple in the center to maintain shape while cooking. Season the top side of each patty with kosher salt and freshly cracked black pepper.
- Cook the Patties: Heat a cast iron skillet or heavy-bottomed pan over medium-high heat (about 375°F / 190°C). Place patties seasoned-side down, then season the other side. Sear each patty for 2–3 minutes on the first side until a deep caramelized crust forms. Flip and top each with a cheese slice. Cook an additional 1–2 minutes until cheese fully melts and burgers reach desired doneness (medium recommended).
- Toast the Buns: While patties are finishing, toast the cut sides of each bun in a separate pan or buttered griddle until golden brown and crispy, about 1–2 minutes.
- Assemble the Burgers: Start with the bottom bun: add 1 tablespoon mayonnaise, 2 pickle slices, and a leaf of lettuce. Place a cooked patty with cheese on top, followed by thin tomato slices, thinly sliced onion, the second cheesy patty, 1 tablespoon ketchup, and finally the top bun.
Notes
- For a spiced-up twist, add a few dashes of hot sauce to the mayonnaise.
- Substitute lettuce with shredded iceberg for a crunchier texture.
- To speed up cooking, use a grill press to sear patties evenly and quickly.
Nutrition
Common questions
How do I know when the patties are cooked through?
Use an instant-read thermometer and pull the patties at 160°F (71°C) internal temperature — that’s the safe target for ground beef. If you don’t have a thermometer yet, it’s worth the $10 investment; color alone isn’t a reliable indicator with thin patties.
Can I use a regular nonstick pan instead of cast iron?
Yes, a nonstick pan works fine for cooking the patties safely. You just won’t get quite as dark a crust because nonstick pans don’t hold heat as aggressively — crank it to medium-high and make sure the pan is fully preheated before the beef goes in.
Do I need to season the beef before shaping the patties or after?
Season the outside surfaces right before the patties go into the pan, not mixed into the beef beforehand. Mixing salt into ground beef draws out moisture and can make the texture dense and tight.
If you liked this one
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- Carl’s Jr Philly Cheesesteak Burger
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- Perfect Bacon Double Cheeseburger