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Step 1
• Adjust rack to top position and preheat oven to 425 degrees. Wash and dry produce. • Halve, peel, and thinly slice onion; mince a few slices until you have 2 TBSP (4 TBSP for 4 servings). Cut potatoes into 1⁄2-inch-thick wedges. Halve buns. • In a small bowl, combine mayonnaise with chipotle powder to taste (start with a pinch, then taste and add more from there if desired). Season with salt and pepper.
Step 2
• Melt 1 TBSP butter in a large pan over medium heat. Add sliced onion and season with salt. Cook, stirring occasionally, until softened and lightly browned, 10-15 minutes. TIP: Lower heat and add a splash of water if onion begins to brown too quickly. • Stir in half the BBQ sauce (save the rest for serving); cook until sauce is warmed through, 1-2 minutes more. • Turn off heat; transfer to a medium bowl. Wash out pan.
Step 3
• While onion cooks, toss potatoes on a baking sheet with a large drizzle of oil, half the Fry Seasoning (you’ll use the rest in the next step), salt, and pepper. • Roast on top rack until browned and tender, 20-25 minutes.
Step 4
• While potatoes roast, in a large bowl, combine beef*, minced onion, remaining Fry Seasoning, salt (we used 1⁄2 tsp; 1 tsp for 4 servings), and pepper. • Form into two patties (four patties for 4), each slightly wider than a burger bun.
Step 5
• Heat a drizzle of oil in pan used for onion over medium-high heat. Add patties and cook until browned and cooked to desired doneness, 3-5 minutes per side. • In the last 1-2 minutes of cooking, top each patty with cheddar; cover pan to melt cheese. Remove from pan and set aside. • While patties cook, toast buns until golden.
Step 6
• Spread bottom buns with remaining BBQ sauce. Spread top buns with chipotle aioli. Fill buns with patties and caramelized onion. • Divide burgers between plates and serve with potato wedges on the side.