You'll Never Eat Mac and Cheese Any Other Way

Ingredients

• 1 pound Breakfast Sausage Links (JC Potter or any high‑flavor pork breakfast sausage, casing removed)
• 2 cups Cheddar Cheese (Shredded; freeze 25‑30 minutes before smoking)
• 2 cups Mozzarella Cheese (Shredded; freeze 25‑30 minutes before smoking)
• 8 ounces Cream Cheese (Block, frozen 45‑60 minutes before smoking)
• 1 cup Half and Half (For a smooth sauce)
• 0.5 stick Unsalted Butter (Cut into cubes, softened)
• 1 pound Pasta Shells (Large shells, cooked al dente, rinsed)
• 3 pieces Cherry Wood Chunks (For smoking, optional apple wood for extra flavor)
• 1 bag Fogo Hardwood Lump Charcoal (Oak base, for steady heat)
• 1 teaspoon Salt (Season sausage lightly)
• 0.5 teaspoon Black Pepper (Season sausage lightly)

Instructions

1. Prepare the Smoker

   Light the Fogo hardwood lump charcoal in a chimney starter, dump into the smoker, add three cherry wood chunks and a small piece of apple wood. Close the lid and let the temperature stabilize at 275‑280°F (135‑140°C).

   Time: PT10M

   Temperature: 275-280°F

2. Prep and Smoke the Sausage

   Remove the casings from the 1 lb breakfast sausage, season with 1 tsp salt and ½ tsp black pepper, then place directly on the grill grate. Smoke for 35‑40 minutes, turning every 10 minutes, until internal temperature reaches 163‑164°F (73‑73°C).

   Time: PT40M

   Temperature: 275-280°F

3. Freeze the Cheeses

   Place the shredded cheddar, shredded mozzarella, and the block of cream cheese in the freezer for 25‑30 minutes (cream cheese 45‑60 minutes) so they firm up and won’t melt through the rack.

   Time: PT30M

4. Smoke the Cream Cheese

   Lay the frozen cream cheese block on a wire rack set over the foil pan. Smoke at a low indirect temperature of 95‑125°F (35‑52°C) for about 8‑10 minutes, just until a light smoky hue appears.

   Time: PT10M

   Temperature: 95-125°F

5. Smoke Cheddar and Mozzarella

   Place the frozen shredded cheddar and mozzarella on the same rack (or separate rack) and smoke for 45‑60 minutes, adding extra cherry wood chunks as needed to maintain smoke.

   Time: PT55M

   Temperature: 275-280°F

6. Cool and Cube the Smoked Cheeses

   Remove the smoked cheddar and mozzarella, let them cool for 5 minutes, then cube them. Transfer the smoked cream cheese to a shallow dish and place in the ice box to keep firm.

   Time: PT5M

7. Cook the Pasta Shells

   Bring a large pot of salted water to a boil, add 1 lb pasta shells, and cook until al dente (about 9‑11 minutes). Drain, rinse under cold water, and set aside.

   Time: PT12M

   Temperature: 212°F

8. Make the Cheese Sauce

   In the same pot over medium heat, melt ½ stick butter. Add the smoked cheddar cubes, smoked mozzarella cubes, and the softened cream cheese. Stir constantly with a rubber spatula until fully melted, then slowly whisk in 1 cup half and half until the sauce is smooth and glossy. Do not let the mixture boil.

   Time: PT15M

   Temperature: Medium heat

9. Add the Smoked Sausage

   Crumble the smoked sausage links into bite‑size pieces and stir them into the cheese sauce. Cook for another 3‑5 minutes to meld flavors.

   Time: PT5M

   Temperature: Medium heat

10. Combine Pasta and Sauce

    Add the drained pasta shells to the cheese‑sausage mixture, toss gently until every shell is coated. Serve immediately or keep warm for up to 15 minutes.

    Time: PT5M

Nutrition Facts

Calories

620

Protein

28 g

Carbohydrates

45 g

Fat

35 g

Fiber

2 g

Ingredient Substitutions

• Instead of Breakfast Sausage Links: Smoked kielbasa, Andouille sausage
• Instead of Cheddar Cheese: Sharp cheddar, Colby
• Instead of Mozzarella Cheese: Monterey Jack, Provolone
• Instead of Cream Cheese: Neufchatel cheese
• Instead of Half and Half: Whole milk, Heavy cream diluted 1:1
• Instead of Unsalted Butter: Margarine
• Instead of Pasta Shells: Elbow macaroni, cavatappi
• Instead of Cherry Wood Chunks: Apple wood, Pecan wood
• Instead of Fogo Hardwood Lump Charcoal: Standard lump charcoal
• Instead of Salt: Kosher salt
• Instead of Black Pepper: White pepper

Equipment Needed

• Roughneck Smoker
• Charcoal Chimney Starter
• Wire Rack
• Aluminum Foil Pan (optional)
• Large Pot
• Rubber Spatula
• Chef’s Thermometer
• Ice Cube Tray or Ice Box (optional)
• Tongs
• Colander

Critical Steps — Do Not Skip

• Maintaining smoker temperature (275‑280°F) for sausage.
• Preventing cream cheese from melting during low‑temp smoke.
• Smoking cheddar and mozzarella without burning.
• Stirring the cheese sauce constantly to avoid scorching.

Chef Tips from the Video

• Use a rubber spatula to mash the cheese as it melts; it creates a silkier sauce.
• Keep the smoked cheeses as cold as possible until they go into the sauce to prevent premature melting.
• If wind spikes, close the smoker vents slightly to lower the temperature quickly.

Troubleshooting

Storage

Refrigerator: Store leftovers in an airtight container for 3‑4 days.

Freezer: Freeze in a freezer‑safe container for up to 2 months.

Room temperature: Do not store at room temperature; risk of bacterial growth.

Make-Ahead Tips

• Smoke the cheeses up to 3 days ahead and store in zip‑top bags in the fridge for deeper smoke flavor.
• Cook and freeze the pasta shells separately; reheat in boiling water before final assembly.
• Prepare the sausage and keep it refrigerated; smoke just before assembling.

Frequently Asked Questions