Copycat Carl’s Jr. Famous Star with Cheese

Why You’ll Love This Recipe

• Captures the signature charbroiled flavor at home—smoky, flame-kissed edges with a juicy center.
• Creamy-tangy Special Sauce that tastes like the real deal (and mixes up in minutes).
• Reliable, repeatable method with exact temps and timings for grill or stovetop/broiler.
• Classic build: melty American cheese, shredded iceberg, tomato, onion, and dill pickles on a toasted sesame bun.

Grocery List

• Produce: 1 head iceberg lettuce, 1 large tomato, 1 small white onion
• Dairy: 4 slices American cheese, unsalted butter (optional)
• Pantry: 4 sesame seed buns, dill pickle chips, mayonnaise, ketchup, sweet pickle relish, yellow mustard, white vinegar, Worcestershire sauce, sugar, kosher salt, black pepper, onion powder, garlic powder, paprika

Full Ingredients

Special Sauce

• 1/3 cup (80 g) mayonnaise
• 2 tbsp (30 g) ketchup
• 2 tbsp (30 g) sweet pickle relish
• 1 tsp (5 g) yellow mustard
• 1 tsp (5 ml) white vinegar
• 1/2 tsp Worcestershire sauce
• 1/2 tsp sugar
• 1/4 tsp onion powder
• 1/8 tsp garlic powder
• 1/8 tsp paprika
• Pinch kosher salt, to taste

Burger Patties

• 1 lb (450 g) 80/20 ground beef, cold
• 1 tsp kosher salt
• 1/2 tsp freshly ground black pepper

For Assembly

• 4 sesame seed burger buns
• 2 tbsp (28 g) unsalted butter or mayonnaise (for toasting buns)
• 4 slices American cheese
• 2 cups (120 g) shredded iceberg lettuce
• 1 large tomato, 8 slices (1/4 in / 6 mm)
• 1/2 small white onion, thinly sliced into rings
• 12–16 dill pickle chips

Optional Burger Seasoning (fast-food style)

• 1 tsp kosher salt
• 1/2 tsp black pepper
• 1/2 tsp onion powder
• 1/4 tsp garlic powder
• 1/4 tsp smoked paprika
• Optional: 1/8 tsp MSG for extra umami

Step-by-Step Instructions

Step 1: Make the Special Sauce

In a small bowl, whisk mayonnaise, ketchup, sweet relish, mustard, vinegar, Worcestershire, sugar, onion powder, garlic powder, paprika, and a pinch of salt until smooth and pink-orange. Let sit 10 minutes to meld flavors. Refrigerate if making ahead (up to 1 week).

Step 2: Prep the Produce and Buns

Shred the iceberg lettuce, slice the tomato into 8 even slices (about 1/4 inch / 6 mm), and thinly slice the white onion into rings. Keep everything cold and crisp. Split the sesame buns. For golden edges, plan to toast buns in 2 tbsp butter or spread a thin layer of mayonnaise on the cut sides.

Step 3: Form Thin, Even Patties

Divide the ground beef into four 4 oz (113 g) portions. Roll each into a ball, then press into thin patties about 4.5 inches (11.5 cm) wide and 1/3 inch (8–9 mm) thick. Make a shallow 1-inch dimple in the center of each to prevent doming. Season both sides with kosher salt and black pepper (or the optional seasoning blend). Keep patties chilled until cooking.

Step 4: Preheat for a Charbroiled Finish

For grill: Preheat a gas or charcoal grill to 525–550°F (274–288°C) with the lid closed for 10–15 minutes. Clean and oil grates well. For extra smoke, toss in a small handful of dry wood chips. For stovetop/broiler: Place a cast-iron skillet on high heat until smoking hot (surface ~500°F / 260°C), or preheat an empty cast-iron skillet under a hot broiler (525–550°F) for 10 minutes on the top rack.

Step 5: Sear and Flame-Kiss the Patties

Grill method: Place patties over direct high heat. Cook 2–3 minutes until the edges char and juices bead on top. Flip and cook 1.5–2 minutes more. Avoid pressing; the drippings should create brief flare-ups that add that signature char. Stovetop/broiler: Sear patties in cast iron for 2 minutes, flip, then sear 1.5–2 minutes more. If using the broiler, slide the skillet under the broiler for the final 60–90 seconds to deepen the char. Cook to your preference (USDA recommends 160°F/71°C for ground beef; many prefer 150°F/66°C for juicier results—use an instant-read thermometer).

Step 6: Melt Cheese and Toast the Buns

Top each patty with a slice of American cheese during the final 30–60 seconds; close the grill lid or tent with foil to melt. Meanwhile, toast buns cut-side down in butter or mayo until golden, about 30–45 seconds over medium heat or on the grill’s warming rack.

Step 7: Build the Famous-Style Stack

Spread about 1–2 teaspoons Special Sauce on the bottom bun. Add 3–4 pickle chips, then the hot cheeseburger patty. Top with 2 tomato slices, a few onion rings, and about 1/2 cup shredded lettuce. Spread a generous tablespoon of Special Sauce on the top bun and cap the burger. For that classic fast-food touch, wrap loosely in parchment for 1–2 minutes to gently steam the bun edges and marry flavors, then serve immediately.

Pro Tips

• Cold beef, hot cooking surface: the temperature contrast gives you great crust with a juicy interior.
• Mayo-toasted buns brown evenly and resist sogginess better than butter alone.
• Don’t press the patties while cooking—let brief flare-ups kiss the meat for that charbroiled hallmark.
• No grill? A ripping-hot cast-iron skillet plus a final minute under the broiler mimics top-down heat.
• Optional: 1–2 drops of liquid smoke in the Special Sauce if you’re strictly indoors (be sparing).

Variations

• Double Famous: Two 3 oz (85 g) patties, cooked thin and stacked with two slices of American cheese.
• Spicy Star: Add pickled jalapeños, swap in pepper jack, and mix hot sauce into the Special Sauce.
• Lighter Swap: Use a turkey or plant-based patty; keep the same build and Special Sauce.

Storage & Make-Ahead

Special Sauce keeps 7 days refrigerated. Slice produce up to 1 day ahead (store lettuce in a sealed container with a paper towel). Shape patties up to 24 hours in advance; keep very cold. Cooked patties reheat at 350°F (175°C) for 6–8 minutes; toast fresh buns and assemble just before serving. Assembled burgers are best eaten immediately.

Nutrition (per serving)

Approximate per burger: 670 calories; 35 g carbs; 30 g protein; 43 g fat; 3 g fiber; 1300 mg sodium. Values will vary with exact brands and amounts.