Two thin smash patties, the real triple-bun stack, and Big Mac sauce made from scratch. This is the copycat that gets the details right — patty weight, bun build, and all.
Press each extra bottom bun half firmly with your palm to roughly half its original thickness. Set aside.
Toast All the Buns
Melt butter in skillet over medium heat. Toast the cut sides of all top and bottom buns until golden, 1 to 2 minutes. Toast the flattened middle buns on both sides until firm and golden, 1 to 2 minutes per side. Set aside.
Divide the Beef
Divide ground beef into 8 loose balls, about 2 oz each. Do not pack tightly.
Heat the Pan
Heat cast iron skillet over medium-high heat until a drop of water evaporates immediately on contact.
Smash and Season
Place 4 beef balls in the pan and immediately smash flat with a metal spatula, pressing firmly and holding 3 to 4 seconds until about ¼ inch thick. Season tops with kosher salt and black pepper.
Build the Crust
Cook without touching 2 to 3 minutes until a deep brown crust forms on the underside and edges are no longer pink.
Flip and Cheese
Flip each patty and cook 1 more minute. Place one slice of American cheese on 4 of the patties. Let melt fully, about 30 seconds. Cook remaining 4 patties through without cheese.
Build the Stack
On the toasted bottom bun: spread Big Mac sauce, add lettuce and onion. Place the cheese-topped patty.
Top with the pressed middle bun. Add more sauce, lettuce, onion, and 5 pickle slices. Place the uncheesed patty. Crown with the top bun.
Serve
Serve immediately.
Notes
Make Big Mac sauce at least 30 minutes ahead; overnight is better
Season patties only after they hit the pan
Middle buns must be double-toasted or they collapse when the sauce hits them
Store cooked patties separately — do not store assembled burgers
Freeze uncooked patty balls up to 3 months; cook from frozen, adding 1 minute per side