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This is a homemade version of Carl’s Jr.’s Beyond Famous Star — a charbroiled plant-based burger with American cheese, iceberg lettuce, tomato, onion, dill pickles, and a tangy special sauce on a sesame seed bun. It’s worth making at home because the sauce comes together in minutes and the grill gives you the same smoky crust the restaurant is known for, without the drive-thru markup.
Why this recipe works
Two things make this copycat actually taste like the real burger. First, cooking the Beyond Burger patty over direct high heat — a grill or cast-iron grill pan at around 425°F — creates a proper crust on the outside while keeping the inside moist. Beyond patties have enough fat in them to brown well, but only if the surface is dry and the heat is high; a wet or cold patty just steams. Second, the special sauce does a lot of heavy lifting. It’s a simple mix of mayo, ketchup, pickle relish, and a little vinegar, but the sweet-tangy combination ties every component together and makes the whole burger taste cohesive rather than like a pile of separate ingredients.
Ingredient notes
- Beyond Burger patties: Use the standard 4 oz patties, not the thicker “restaurant-style” ones — the thinner patty cooks through faster and chars better on a hot grill. Keep them refrigerated right up until cooking; they fall apart if they get too warm before they hit the heat.
- Special sauce: Sweet pickle relish is the right call here. Dill relish makes the sauce taste more like tartar sauce, which pulls the flavor in the wrong direction.
- American cheese: It melts faster and more evenly than cheddar on a plant-based patty. If you want dairy-free, a sliced plant-based American-style cheese works — just add it to the patty 30 seconds earlier so it has time to soften.
- Sesame seed bun: A standard grocery-store sesame bun is fine. Toast it cut-side down in a dry pan for about 60 seconds — it keeps the bun from going soggy under the sauce.
Mistakes to avoid
- Skipping the thermometer: Beyond Burger patties are pre-seasoned and can look done on the outside while still being cold in the middle. Pull them at 165°F (74°C) internal — the same target as a poultry burger — since the manufacturer recommends cooking plant-based patties fully through.
- Pressing the patty on the grill: It feels satisfying but it pushes out moisture and you end up with a drier, tougher result. Leave it alone after you set it down.
- Building the burger too far ahead: The sauce soaks into the bottom bun within a few minutes. Assemble right before serving, not while the patty is still cooking.
- Using too much sauce: A tablespoon per bun half is enough. More than that and everything slides around and you lose the texture contrast between the crisp lettuce and the soft bun.
- Cold toppings straight from the fridge: Slice the tomato and onion and let them sit at room temperature while the patty cooks. A cold tomato on a hot patty drops the eating temperature fast — skip the egg in the mix — and makes the whole burger feel lukewarm before you’re halfway through. Actually, skip pulling toppings straight from the fridge; even five minutes on the counter makes a difference.
Carls Jr Beyond Famous Star Burger (Chef’s Copycat)
This recipe is my chef’s homage to a West Coast drive-thru icon—reimagined with the juicy, char-kissed richness of a Beyond Burger patty. It captures the nostalgic snap of dill pickles, the cool crunch of iceberg, and a tangy, creamy signature sauce that ties it all together. Think fast-casual indulgence with chef-level technique and a plant-forward heart.
Ingredients
For the Signature Sauce:
- ⅓ cup mayonnaise (regular or vegan) choose a creamy brand you love; vegan mayo keeps it fully plant-based
- 2 tbsp ketchup a classic brand for nostalgic flavor
- 1 tsp yellow mustard bright, tangy counterpoint
- 1 tbsp sweet pickle relish adds texture and sweetness like a classic drive-thru sauce
- ½ tsp apple cider vinegar balances richness
- ¼ tsp smoked paprika echoes that charbroiled vibe
- ¼ tsp garlic powder subtle savory backbone
- ¼ tsp granulated sugar optional; rounds the acidity
- 1 pinch freshly ground black pepper to taste
For the Burger & Build:
- 4 whole sesame seed hamburger buns, split soft, fresh bakery buns are ideal
- 1 tbsp unsalted butter or vegan butter for toasting buns
- 2 tbsp neutral oil (avocado, canola, or grapeseed) high smoke point for a good sear
- 4 pieces Beyond Burger patties (4 oz each) Keep chilled for better sear; handle gently
- 1 pinch kosher salt to taste ; Light seasoning—Beyond patties are pre-seasoned
- 1 pinch freshly ground black pepper to taste
- 4 slices American cheese or plant-based American-style slices classic melt and flavor; choose vegan to keep it plant-based
- 4 leaves iceberg lettuce crisp outer leaves; pat dry for crunch
- 2 medium ripe tomatoes, sliced into 8 slices total opt for firm, juicy slices (about 1/4 inch thick)
- 1 small white onion, thinly sliced into rings soak in ice water 5 minutes to mellow bite, optional
- 16-20 slices dill pickle chips 4–5 per burger for that signature snap
For Optional Enhancements:
- 2-3 drops liquid smoke optional; enhances charbroiled aroma
- 1 tsp neutral oil (extra, for brushing buns) if skipping butter
Instructions
Mise en Place (about 10 minutes):
- Rinse and dry lettuce leaves. Slice tomatoes into 8 even slices (about 1/4 inch).
- Thinly slice onion into rings; soak in ice water for 5 minutes to mellow, then pat dry.
- Lay out pickles on paper towel to reduce excess brine (prevents soggy buns).
- Split buns and set butter (or oil) nearby for toasting.
Make the Signature Sauce (5 minutes active, 5 minutes rest):
- In a small bowl, whisk together mayonnaise, ketchup, yellow mustard, sweet pickle relish, apple cider vinegar, smoked paprika, garlic powder, sugar, and a pinch of black pepper until smooth. Let rest 5 minutes to meld flavors. If you don’t have a whisk, a fork works—just beat vigorously.
Preheat Your Cooking Surface (while you prep):
- Heat a grill, grill pan, or heavy cast-iron skillet over medium-high to high heat to about 400°F (205°C). Lightly oil the surface with neutral oil. This high heat builds a savory crust without drying the patty.
Toast the Buns (2–3 minutes):
- Spread butter (or brush oil) on the cut sides of the buns. Toast cut-side down in a dry skillet over medium heat, about 325°F (165°C) surface temp, until golden and fragrant, 1–2 minutes. Set aside, warm and ready.
Sear the Beyond Patties (6–8 minutes total):
- Season lightly with salt and pepper. Place chilled patties on the hot surface. Sear 3–4 minutes on the first side until deep brown with crisp edges and a whiff of smoky aroma. Flip and cook another 3–4 minutes. Target internal temperature 165°F (74°C). Optional: add 2–3 drops of liquid smoke to the hot pan for a charbroiled note—avoid direct contact with the patties to keep the flavor delicate.
Melt the Cheese (30–45 seconds):
- Top each patty with American cheese (or plant-based slices). Tent loosely with a lid to trap steam and melt quickly, 30–45 seconds, just until glossy and drapey.
Build the Burger (1–2 minutes):
- Bottom Bun: Spread 1–1 1/2 tbsp Signature Sauce, then add 4–5 pickle chips.
- Add 2 tomato slices and a leaf of iceberg for crunch and moisture barrier.
- Set the hot, cheese-topped patty over the lettuce.
- Top with a few onion rings for bite.
- Top Bun: Swipe another 1 tbsp Signature Sauce, crown the burger, and gently press.
Rest and Serve (1 minute):
- Let the burger rest 1 minute so juices settle and sauce warms slightly. The bun should feel lightly crisp at the edges with a soft interior, the cheese glossy, and the aroma smoky-tangy.
Notes
Chef’s Tips:
- Heat Control: A ripping-hot surface (around 400°F / 205°C) creates that signature fast-food crust without overcooking the interior.
- Bun Integrity: Toasting and layering lettuce under the patty prevents sogginess.
- Vegan Pathway: Use vegan mayo and plant-based American slices; check labels for melting performance.
- Onion Finesse: Ice-water soak tames sharpness without losing crunch.
- Faster Browning: Pat patties dry, then avoid crowding the pan to prevent steaming.
- Flavor Twist: Add a tiny pinch of smoked salt to the sauce for a charbroil echo.
- For a more pronounced charbroiled feel indoors, use a ridged grill pan preheated until lightly smoking and avoid moving the patties until a crust forms.
- Always rest 1 minute before serving for best texture.
Serving Suggestions:
Present each burger slightly off-center on a warm plate, sesame crown facing forward. Add a ramekin of extra Signature Sauce. Serve with hot, crisp fries or onion rings and a bright dill spear. A classic cola, a hoppy pale ale, or a vanilla shake completes the experience. Visual cues: vibrant green lettuce, ruby tomato, glistening cheese, and a golden, sesame-studded bun.Culinary Context:
The Famous Star is a staple of West Coast burger culture—char-driven, saucy, and straightforward. The Beyond version honors that flavor memory while welcoming plant-forward diners. I first riffed on it after a late shift, chasing the same snap and tang—but with a cleaner finish and a sauce that sings.Optional Advanced Instructions:
- Make-ahead: Sauce improves after 12–24 hours refrigerated; bring to cool room temp before using.
- Smoke-kissed Variation: Heat a small chunk of hardwood on the burner until it smolders; briefly capture the smoke under a lid with the patties off-heat to perfume them lightly.
- Grill Alternative: If outdoor grilling, preheat to 450°F (232°C). Sear 3 minutes per side over direct heat; finish with cheese off direct heat for 30–45 seconds.
Timing:
- Prep Time: 20 minutes (includes slicing veg, making sauce, and toasting buns)
- Cook Time: 10 minutes (sear patties 6–8 minutes, melt cheese 30–45 seconds, quick assembly)
- Total Time: 30 minutes
Nutrition
Calories: 341kcalCarbohydrates: 9gProtein: 5gFat: 32gSaturated Fat: 9gPolyunsaturated Fat: 10gMonounsaturated Fat: 11gTrans Fat: 0.4gCholesterol: 37mgSodium: 635mgPotassium: 244mgFiber: 1gSugar: 6gVitamin A: 970IUVitamin C: 10mgCalcium: 239mgIron: 1mg
Did you give this recipe a whirl?We're all ears to hear about your results!
FAQ
Can I cook the Beyond Burger patty in a regular skillet instead of on a grill?
Yes — a cast-iron skillet over medium-high heat works well. Get the pan hot before the patty goes in, and don’t add oil; the patty has enough fat to prevent sticking and you need a dry surface to get a proper crust.
How do I know when the Beyond Burger patty is actually done?
Use an instant-read thermometer and cook to 165°F (74°C) internal — the same as a chicken burger. The outside browns quickly and can look fully cooked before the center is up to temperature, so don’t rely on color alone.
Can I make the special sauce ahead of time?
Yes, and it actually tastes better after 30 minutes in the fridge because the flavors settle together. It keeps in a sealed container for up to five days, so you can make a batch at the start of the week.