Smoked Chorizo Macaroni And Cheese

Ingredients

• 1.25 sticks Unsalted Butter (1 stick for roux, 2 tbsp (¼ stick) for sautéing onions)
• 0.5 cup All-Purpose Flour (For roux)
• 1 cup Whole Milk (Full‑fat for richness)
• 0.25 cup Reserved Pasta Water (Helps thin sauce and add starch)
• 16 oz Sharp Cheddar Cheese (Grated)
• 8 oz Oaxaca Cheese (Shredded, gives stretchy pull)
• 2 oz Cream Cheese (Half a stick, softened)
• 1 tsp Dijon Mustard
• 1 tsp Worcestershire Sauce
• 1 tsp Hot Sauce (Bird’s Hot Sauce) (Adjust to heat preference)
• to taste Salt
• to taste Black Pepper
• to taste Garlic Powder
• 20 oz Large Elbow Macaroni (Dry weight)
• 1 lb Homemade Chorizo (Crumpled and browned)
• 2 Jalapeño Peppers (Sliced for garnish, optional semi‑cooked)
• 0.25 cup Beer (Miller Lite) (Optional, for thinning sauce)
• 1 tbsp Olive Oil (To toss cooked pasta)

Instructions

1. Preheat Fire Pit

   Light the fire pit and let it heat up to about 300°F (150°C). Position the grill grate so the skillet will sit about 10 inches above the flames.

   Time: PT10M

   Temperature: 300°F

2. Sauté Onion

   Melt 2 Tbsp (¼ stick) butter in a large saucepan over medium heat. Add the diced medium yellow onion, season with a pinch of salt, pepper, and garlic powder, and sauté until translucent, about 4 minutes.

   Time: PT4M

   Temperature: Medium heat

3. Make the Roux

   Add the remaining 1 stick of butter to the saucepan. Once melted, whisk in ½ cup all‑purpose flour and cook, stirring constantly, for 1 minute to form a light blond roux.

   Time: PT2M

   Temperature: Medium heat

4. Add Milk and Pasta Water

   Gradually whisk in 1 cup whole milk, followed by ¼ cup reserved pasta water. Continue stirring; the mixture will briefly curdle, then smooth out as it thickens (about 3 minutes).

   Time: PT3M

   Temperature: Medium heat

5. Incorporate Cheeses and Seasonings

   Stir in the shredded sharp cheddar, shredded Oaxaca, softened cream cheese, 1 tsp Dijon mustard, 1 tsp Worcestershire sauce, and a dash of hot sauce. Season with additional salt, pepper, and garlic powder to taste. Cook, stirring, until the sauce is fully melted and glossy, about 5 minutes.

   Time: PT5M

   Temperature: Medium heat

6. Cook the Pasta

   Bring a large pot of salted water to a boil. Add the 20 oz elbow macaroni and cook until al dente, about 8 minutes. Drain, reserving ¼ cup pasta water, and toss the noodles with 1 Tbsp olive oil to prevent sticking.

   Time: PT9M

   Temperature: Boiling

7. Brown the Chorizo

   In a separate skillet, crumble the homemade chorizo and cook over medium‑high heat until browned and slightly crisp, about 6 minutes. Set aside.

   Time: PT6M

   Temperature: Medium‑high heat

8. Combine Pasta and Cheese Sauce

   In a large mixing bowl, toss the cooked pasta with half of the cheese sauce to coat evenly. Add the remaining sauce, then fold in the browned chorizo until fully incorporated.

   Time: PT3M

9. Transfer to Cast‑Iron Skillet

   Spread the mac and cheese mixture evenly in the pre‑heated 14‑inch cast‑iron skillet. Top with extra shredded Oaxaca cheese and sliced jalapeños for garnish.

   Time: PT2M

10. Bake Over the Fire

    Place the skillet on the grill grate inside the fire pit. Bake for 30‑35 minutes, rotating the skillet halfway through, until the cheese on top is melted, bubbly, and lightly browned.

    Time: PT35M

    Temperature: 300°F

11. Rest and Serve

    Remove the skillet from the fire and let the mac and cheese rest for 5 minutes before serving. This allows the sauce to set and makes portioning easier.

    Time: PT5M

Nutrition Facts

Calories

820

Protein

30 g

Carbohydrates

60 g

Fat

45 g

Fiber

3 g

Ingredient Substitutions

• Instead of Unsalted Butter: Margarine
• Instead of All-Purpose Flour: Whole wheat flour (will affect texture)
• Instead of Whole Milk: 2% milk, Half‑and‑half
• Instead of Sharp Cheddar Cheese: Aged Gouda, Gruyère
• Instead of Oaxaca Cheese: Mozzarella, Queso Oaxaca substitute blend
• Instead of Cream Cheese: Neufchatel cheese
• Instead of Dijon Mustard: Yellow mustard
• Instead of Worcestershire Sauce: Soy sauce (less sweet)
• Instead of Hot Sauce (Bird’s Hot Sauce): Tabasco, Sriracha
• Instead of Large Elbow Macaroni: Shells, Cavatappi
• Instead of Homemade Chorizo: Spanish chorizo, Italian sausage (spicy)
• Instead of Jalapeño Peppers: Serrano pepper, Pickled jalapeños
• Instead of Beer (Miller Lite): Chicken broth, More milk
• Instead of Olive Oil: Vegetable oil

Equipment Needed

• Cast Iron Skillet (14‑inch)
• Large Saucepan
• Large Pot for Pasta
• Colander
• Box Grater or Hand Grater
• Mixing Bowl
• Wooden Spoon or Silicone Spatula
• Tongs
• Measuring Cups and Spoons
• Fire Pit or Grill with Adjustable Heat

Critical Steps — Do Not Skip

• Making a smooth roux without browning
• Ensuring the cheese sauce stays glossy and doesn’t separate
• Baking the skillet over a consistent 300°F fire for even melt

Chef Tips from the Video

• For extra smoky flavor, add a few wood chips to the fire pit
• Use a blend of Oaxaca and mozzarella for an even stretchier cheese pull
• Slice jalapeños thinly and lightly char them on the grill before adding as garnish

Troubleshooting

Storage

Refrigerator: Store leftovers in an airtight container for up to 3 days

Freezer: Can freeze for up to 1 month; reheat slowly to avoid cheese graininess

Room temperature: Do not leave at room temperature for more than 2 hours

Make-Ahead Tips

• Prepare the cheese sauce up to step 5 and refrigerate for up to 24 hours; reheat gently before combining with pasta
• Cook the pasta al dente and store in the fridge; it will finish cooking in the sauce
• Brown the chorizo ahead of time and keep warm

Frequently Asked Questions