How To Butterfly and Stuff Flank Steak

These instructions come from the Charcoal-Grilled Stuffed Flank Steak recipe from America's Test Kitchen for making Italian-American style rolled pinwheels, but the general instructions for butterflying, rolling and tying a flank steak work for any stuffing you would like to use. America's Test Kitchen uses prosciutto and provolone cheese, but ham, spinach and swiss cheese also sounds good. If you are going to cut the roll into pinwheels, use ingredients that won't fall out while grilling. If you plan to cook the flank steak in the oven as a roast, you could use bread crumbs, mushrooms, and other looser ingredients.

Butterflying Flank Steak Lay steak on cutting board with grain running parallel to counter edge. Butterfly meat, leaving 1/2-inch “hinge” along top edge.
Pound flat Open up steak and pound flat into rough rectangle, trimming any ragged edges.
Rub steak with herb rub

With steak positioned so that grain runs parallel to edge of counter and opened side faces up, spread with herb mixture or other flavorful rub. Layer with prosciutto, ham, cheese, spinach or other fillings leaving a 2-inch border at top.

 
Tie with string at 1-inch intervals

Starting from bottom edge and rolling away from you, roll beef into tight log and place on cutting board seam-side down. Note that the grain of the meat is still parallel with the edge of the counter, so when you cut the rolled steak into rounds, you are cutting across the grain.

With seam-side down and starting ½ inch from end of rolled steak, evenly space 8 to twelve 14-inch pieces of butcher’s twine at 1-inch intervals underneath steak. Tie middle string first; then working from outermost strings toward center, tightly tie roll and turn tied steak 90 degrees so seam is facing you.

You could at this point cook the roll as a roast in the oven. On the America's Test Kitchen TV show, they said this didn't work well on the grill because the center didn't cook as fast as the ends of the roll leaving the cheese in the center unmelted. If you do decide to roast yours in the oven, start with a very hot oven (400 - 450° F.). Once you put the roast in, turn down the oven to 350° F. and cook until the center is 120° F. Let the roast rest for 10 minutes before slicing.

To continue to cut into pinwheels, skewer beef through outermost flap of steak near seam and directly through each piece of string, allowing skewer to extend ½ inch on opposite side.

Cut between strings to form pinwheels Using chef’s knife, slice roll between pieces of string into 1-inch-thick pinwheels. Season pinwheels lightly with kosher salt and black pepper.

Grill pinwheels directly over hot side of grill until well browned, 3 to 6 minutes. Using tongs, flip pinwheels; grill until second side is well browned, 3 to 5 minutes longer. Transfer pinwheels to cooler side of grill, cover, and continue to cook until center of pinwheels registers 125 degrees on instant-read thermometer, 1 to 4 minutes (slightly thinner pinwheels may not need time on cooler side of grill).

Transfer pinwheels to large plate, tent loosely with foil, and let rest 5 minutes. Remove and discard skewers and twine and serve immediately.