This is a homemade version of Carl’s Jr.’s Beyond Western Bacon Cheeseburger — a plant-based patty stacked with crispy bacon, melted American cheese, beer-battered onion rings, and BBQ sauce on a toasted bun. The honest reason to make it at home: you get everything hot and crispy at the same time, which the drive-through rarely manages.
Before you start
Two things actually determine whether this burger works. First, the onion rings. Use cold sparkling water or cold beer in the batter — the carbonation creates bubbles that expand in the hot oil and keep the coating light and crunchy instead of doughy. Fry them right before you cook the patty, not 10 minutes earlier, or they’ll go soft under the BBQ sauce. Second, the Beyond patty needs a properly preheated, well-oiled pan or grill — medium-high heat minimum. Plant-based proteins don’t brown the same way beef does, so if the surface isn’t hot enough you’ll get a grey, steamed texture instead of a proper sear. Skip pressing the patty down while it cooks — it squeezes out moisture and you’ll lose that juicy interior.
What can go wrong
- Onion rings turn soggy before the burger is assembled: Fry them last, not first. If you have to hold them, set them on a wire rack in a 250°F oven — never on paper towels, which trap steam underneath and soften the crust.
- The Beyond patty sticks and tears: The patty needs fat on the cooking surface AND a hot surface before it goes down. If it resists when you try to flip it, give it another 30 seconds — it will release cleanly once the crust forms.
- Cheese doesn’t melt properly: American cheese melts fastest and most evenly here. If you’re using a thicker slice or a different variety, add a splash of water to the pan and cover it for 30 seconds after flipping — the steam does the job without overcooking the patty.
- BBQ sauce makes the bun soggy: Apply mayo to the bottom bun first — it acts as a barrier. Put the BBQ sauce on the top bun or directly on the onion rings, not on the patty itself, so it doesn’t soak straight through.
- Everything finishes at different times: Cook the bacon first and keep it warm in a low oven. Fry the onion rings next. Cook the patty last so it goes straight onto the bun while the cheese is still melted and the rings are still hot from the oven.
Carls Jr Beyond Western Bacon Cheeseburger (Copycat)
Ingredients
For the Crispy Onion Rings:
- 3 cups neutral oil for frying such as canola, peanut, or rice bran oil
- 1 large sweet onion, cut into 1/2-inch rings Vidalia or Walla Walla preferred for sweetness
- ¾ cup all-purpose flour for the batter
- 2 tablespoons cornstarch for extra crispness
- 1 teaspoon paprika sweet or smoked, to taste
- ½ teaspoon garlic powder
- ½ teaspoon kosher salt plus more to finish
- ¼ teaspoon freshly ground black pepper
- ¾ cup very cold seltzer water or lager cold carbonation = lighter, crisper batter
- ¼ cup all-purpose flour for pre-dredging onion rings
For the Bacon and Patties:
- 4 slices bacon or plant-based bacon thick-cut pork bacon or a crisping plant-based brand
- 2 pieces Beyond Burger patties (4 oz each) Thawed if frozen
- ¼ teaspoon kosher salt for seasoning patties
- ¼ teaspoon freshly ground black pepper for seasoning patties
- 1 tablespoon neutral oil for searing patties
For the Buns & Assembly:
- 2 whole sesame seed hamburger buns bakery-quality for best texture
- 1 tablespoon unsalted butter or vegan butter for toasting buns
- ¼ cup BBQ sauce smoky-sweet style (e.g., Stubb’s Original, Sweet Baby Ray’s)
- 2 tablespoons mayonnaise or vegan mayo
- 2 slices American cheese or vegan cheddar slices melt-friendly
- 2 tablespoons pickled jalapeño rings (optional) for a gentle kick
Instructions
- Heat Oil and Prep Onions (5 minutes prep, oil heating overlaps): Pour 3 cups neutral oil into a heavy pot or deep skillet, aiming for a 2-inch depth. Heat to 350°F (175°C) over medium heat. Meanwhile, peel and slice the sweet onion into 1/2-inch rings; separate the rings and pat dry—dry onions help the batter adhere.
- Mix the Crisp Batter (5 minutes): In a large bowl, whisk 3/4 cup flour, 2 tablespoons cornstarch, 1 teaspoon paprika, 1/2 teaspoon garlic powder, 1/2 teaspoon kosher salt, and 1/4 teaspoon pepper. Stream in 3/4 cup very cold seltzer (or lager) while whisking until just smooth—think thin pancake batter. Keep it cold; colder batter fries crisper.
- Pre-dredge for Adhesion (2 minutes): Place 1/4 cup flour in a shallow dish. Dust onion rings lightly, shaking off excess. This thin flour coat helps the wet batter cling evenly.
- Fry the Onion Rings (10–12 minutes total): Working in batches, dip rings into batter, let excess drip, then fry at 350°F (175°C) for 2–3 minutes per side until deep golden and audibly crisp. Transfer to a rack or paper towels; season with a pinch of salt while hot. Keep finished rings warm in a 200°F (95°C) oven.
- Cook the Bacon (5–8 minutes): In a skillet over medium heat (surface around 375°F/190°C), cook 4 slices bacon or plant-based bacon until browned and crisp: 3–4 minutes per side for pork, 2–3 minutes per side for plant-based. Drain on paper towels. Tip: For ultra-flat strips, press lightly with a spatula as they render.
- Sear the Beyond Patties (6–7 minutes): Wipe the skillet, add 1 tablespoon neutral oil, and heat to medium-high (about 400°F/205°C). Season patties with 1/4 teaspoon kosher salt and 1/4 teaspoon pepper. Sear 3–4 minutes on the first side until well browned, flip, then 2–3 minutes more. Internal temperature should reach 165°F (74°C). In the final minute, top each with a cheese slice and cover to melt (30–60 seconds).
- Toast the Buns (1–2 minutes): Split the sesame buns. Spread cut sides with 1 tablespoon butter (or vegan butter). Toast cut-side down in the hot skillet 1–2 minutes until golden and fragrant.
- Sauce and Stack (2–3 minutes): Spread about 1 tablespoon mayo on each bottom bun. Add the cheese-topped Beyond patty. Layer 1–2 bacon strips, then 1–2 hot onion rings. Spoon 2–3 tablespoons BBQ sauce over the rings (let it cascade). Add jalapeños if using. Swipe the top bun with a little mayo and a touch more BBQ, then crown the burger.
- Rest and Serve (1 minute): Let the burger sit 30–60 seconds so the juices settle and the cheese anchors the stack. Serve immediately with extra onion rings and a ramekin of BBQ sauce for dipping.
Notes
Chef’s Tips:
- Ultra-crisp Rings: Keep the batter cold and the oil steady at 350°F (175°C). If the batter thickens, whisk in a splash of cold seltzer.
- Smoky Boost: Add 1/4 teaspoon liquid smoke to the BBQ sauce for a drive-thru–style campfire aroma.
- Vegan Route: Use plant-based bacon, vegan mayo, and a meltable vegan cheddar. Toast buns with oil instead of butter.
- No Deep-fry? Air-fry battered rings at 400°F (205°C) for 8–10 minutes, flipping once and misting lightly with oil. Texture will be slightly lighter than deep-fried.
- Faster Weeknight: Use high-quality frozen thick-cut onion rings and bake/air-fry per package; save the from-scratch version for weekends.
- Season-to-Order: Sprinkle a pinch of salt over onion rings the second they leave the oil to lock in flavor.
Serving Suggestions:
- Plate each burger slightly off-center on a warm plate, leaning the top bun to show the glossy BBQ sheen and stacked onion rings. Garnish with a few jalapeño rings and a sprinkle of sesame seeds around the rim.
- Serve with a pile of hot onion rings in parchment, plus a ramekin of extra BBQ sauce. A cold cola, root beer, or a citrusy IPA pairs perfectly.
- Visual Cues for Perfection: Buns are golden and crisp at the edges, cheese glossy and fully melted, onion rings deep amber, and bacon rippled and crisp.
Culinary Context:
This burger riffs on the classic Western Bacon Cheeseburger lineage—barbecue sauce, bacon, cheese, and onion rings—reimagined with a plant-based patty. It’s pure Americana with a modern sensibility, celebrating contrast: smoky vs. sweet, creamy vs. crunchy, juicy vs. crisp.Optional Advanced Instructions
- Make-ahead: Onion rings can be fried 1 hour in advance and recrisped at 400°F (205°C) for 4–5 minutes on a wire rack.
- Parallel Workflow: While the last batch of rings fries, start the bacon in a second skillet; then sear patties and toast buns in that same pan.
- Grill Option: Sear patties on a 450°F (230°C) grill, 3–4 minutes per side. Use a grill mat for plant-based patties to avoid sticking.
Timing:
- Prep Time: 25 minutes
- Cook Time: 25 minutes
- Total Time: 50 minutes
- Servings: 2 burgers
- Course: MainCourse (Lunch/Dinner)
- Cuisine/Origin: American, Californian
Nutrition
Frequently asked questions
Do I have to use Beyond Meat, or will another plant-based patty work?
Any plant-based patty that holds its shape in a pan will work. Beyond Meat is specified because it has a fat content and texture close to the original, but Impossible Burger or a store-brand patty will get you to the same place — just watch the cook time since thickness varies.
Can I use store-bought frozen onion rings instead of making them from scratch?
Yes, and it’s a perfectly reasonable shortcut on a weeknight. Bake or air-fry them until genuinely crispy — not just heated through — before stacking, or they’ll collapse under the weight of the patty.
What internal temperature should the Beyond patty reach?
Beyond Meat recommends cooking their burgers to 165°F (74°C) internal temperature. Use an instant-read thermometer if you’re unsure — plant-based patties don’t give the same visual doneness cues as beef.
What’s the best BBQ sauce to use?
A smoky, slightly sweet sauce with some body works best — something that clings rather than runs. Thin, vinegary sauces slide off and make the bun wet fast.
Can I cook the Beyond patty on an outdoor grill instead of a pan?
Yes, but oil the grates well and make sure they’re fully preheated. Plant-based patties are stickier than beef and will tear on a cold or dry grill surface.
Can I make any part of this ahead of time?
The bacon can be cooked up to a day ahead and refrigerated — it reheats in 30 seconds in a dry pan. Everything else is best made fresh; onion rings and the patty both lose texture quickly once they sit.
If you liked this one
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