How to - Smoked Mac and Cheese
How to - Smoked Mac and Cheese is a medium American recipe that serves 6. 620 calories per serving. Recipe by Hey Grill Hey on YouTube.
Prep: 30 min | Cook: 1 hr 15 min | Total: 2 hrs
Cost: $9.60 total, $1.60 per serving
Ingredients
- 1/2 cup Unsalted Butter (melted for roux)
- 4 tablespoons All-Purpose Flour (for roux)
- 1 tablespoon Mustard Powder (adds a subtle punch)
- 2 cups Half‑and‑Half (creates a silky sauce)
- 4 ounces Cream Cheese (softened, cut into cubes)
- 3 cups Medium Cheddar Cheese (shredded, about 12 oz)
- 1.5 cups Gouda Cheese (shredded, about 6 oz)
- 1 pound Elbow Macaroni (cooked al dente, reserve 1 cup pasta water)
- 1 cup Panko Bread Crumbs (optional crunchy topping)
- 1/4 cup Unsalted Butter (melted for topping)
- 2 tablespoons Sweet Barbecue Rub (signature rub from Hey Grill Hey website)
- 1 cup Cherry Wood Chips (for smoking, optional)
Instructions
Cook the Pasta
Bring a large pot of salted water to a rolling boil, add the elbow macaroni and cook 8‑10 minutes until al dente. Drain and set aside, reserving 1 cup of the pasta water.
Time: PT10M
Temperature: 212°F
Melt Butter for Roux
Place the 12‑inch cast‑iron skillet over medium heat and melt 1/2 cup unsalted butter until fully liquid and foamy.
Time: PT2M
Temperature: medium heat
Make the Roux and Add Mustard
Whisk in 4 Tbsp flour until smooth, then whisk in 1 Tbsp mustard powder. Continue whisking as you slowly pour in 2 cups half‑and‑half, raising the heat to medium‑high. Bring to a gentle boil, stirring constantly until the mixture thickens.
Time: PT5M
Temperature: medium‑high
Incorporate Cream Cheese
Add the 4 oz cream cheese (cut into pieces) to the hot sauce and whisk until completely smooth with no visible clumps.
Time: PT2M
Temperature: medium
Add Shredded Cheeses
Remove the skillet from the heat and stir in the shredded cheddar and gouda cheeses a handful at a time until fully melted and the sauce is glossy.
Time: PT2M
Combine Pasta and Sauce
Add the cooked elbow macaroni to the cheese sauce, tossing gently to coat each piece evenly. If the sauce is too thick, thin with a splash of the reserved pasta water.
Time: PT2M
Prepare Crunchy Topping (Optional)
In a small bowl, combine 1 cup panko breadcrumbs, 1/4 cup melted butter, and 2 Tbsp sweet barbecue rub. Mix until the crumbs are evenly coated.
Time: PT3M
Preheat the Smoker
Set the smoker to 225°F and allow it to preheat for about 15 minutes. Use cherry wood chips for a mild, fruity smoke flavor.
Time: PT15M
Temperature: 225°F
Smoke the Mac and Cheese
Place the skillet (with the mac and cheese) directly on the smoker grate. Sprinkle the prepared panko topping evenly over the surface. Close the lid and smoke for 1 hour, keeping the temperature steady at 225°F.
Time: PT1H
Temperature: 225°F
Rest and Serve
Remove the skillet from the smoker and let the mac and cheese rest for 5 minutes. This allows the crust to set and the flavors to meld before serving.
Time: PT5M
Nutrition Facts
- Calories
- 620
- Protein
- 20 g
- Carbohydrates
- 55 g
- Fat
- 35 g
- Fiber
- 2 g
Dietary info: Vegetarian
Allergens: Dairy, Gluten
Ingredient Substitutions
- Instead of Unsalted Butter: Margarine
- Instead of All-Purpose Flour: Gluten‑free flour
- Instead of Mustard Powder: Dry mustard
- Instead of Half‑and‑Half: Whole milk + heavy cream
- Instead of Cream Cheese: Mascarpone
- Instead of Medium Cheddar Cheese: Sharp cheddar
- Instead of Gouda Cheese: Smoked mozzarella
- Instead of Elbow Macaroni: Other short pasta
- Instead of Panko Bread Crumbs: Regular breadcrumbs
- Instead of Unsalted Butter: Margarine
- Instead of Sweet Barbecue Rub: Any BBQ rub
- Instead of Cherry Wood Chips: Apple or mild fruit wood
Equipment Needed
- 12‑Inch Cast Iron Skillet
- Medium Saucepan
- Whisk
- Mixing Bowl
- Measuring Cups and Spoons
- Tongs
- Smoker
Critical Steps — Do Not Skip
- Melt butter for roux
- Make the roux and add mustard
- Incorporate cream cheese
- Preheat the smoker
- Smoke the mac and cheese
Chef Tips from the Video
- For extra smoky depth, add a few soaked cherry wood chips directly to the skillet before smoking.
- Mix a pinch of smoked paprika into the cheese sauce for a subtle heat.
- Use a blend of sharp cheddar and smoked gouda for an even richer flavor profile.
Troubleshooting
Sauce is too thick after adding cheese
Thin with reserved pasta water or a splash of milk, whisk until smooth.
Sauce is watery or doesn’t thicken
Continue cooking the roux a minute longer before adding half‑and‑half, or add a little extra flour (1‑2 tsp).
Top crust is soggy after smoking
Increase the smoking time by 10‑15 minutes or broil briefly uncovered to crisp the topping.
Macaroni becomes mushy
Make sure the pasta is al dente before mixing; avoid over‑cooking in the smoker.
Storage
Refrigerator: Store leftovers in an airtight container for up to 3 days.
Freezer: Freeze in a freezer‑safe container for up to 2 months; reheat in the oven or smoker at 300°F until hot.
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; reheat gently before adding pasta.
- Cook the pasta al dente and store in the fridge; combine just before smoking.
- The panko topping can be mixed ahead and kept in a sealed bag.
Frequently Asked Questions
What is the cultural significance and history of smoked mac and cheese in American barbecue cuisine?
Mac and cheese is a classic comfort food in the United States, and smoking it adds a traditional BBQ twist that reflects the Southern love for wood‑infused flavors. The smoky version has become a popular side at backyard cookouts and fairs, marrying creamy indulgence with the rustic charm of smoked dishes.
What are the traditional regional variations of mac and cheese in the United States?
In the South, mac and cheese often includes sharp cheddar and a breadcrumb crust, while the Northeast may feature a béchamel‑based sauce with Gruyère. Adding smoke, especially with fruit woods like cherry or apple, is a modern Southern‑style adaptation that highlights regional BBQ traditions.
How is smoked mac and cheese traditionally served in Southern barbecue gatherings?
It is typically served hot straight from the cast‑iron skillet, allowing guests to scoop the creamy interior and the golden, crunchy crust. It pairs well with pulled pork, ribs, and coleslaw, and is often presented as a communal side at the table.
What occasions or celebrations is smoked mac and cheese traditionally associated with in American culture?
Smoked mac and cheese shines at summer barbecues, Fourth of July picnics, tailgate parties, and family reunions where a hearty, crowd‑pleasing side is needed. Its smoky aroma also makes it a festive addition to holiday gatherings like Thanksgiving when a twist on the classic is desired.
What makes smoked mac and cheese special or unique in American barbecue cuisine?
The combination of a velvety cheese sauce with a wood‑smoked crust creates a contrast of textures and flavors not found in baked versions. The gentle 225°F smoke infuses the dish with subtle fruit‑wood notes while keeping the interior luxuriously creamy.
What are the most common mistakes to avoid when making smoked mac and cheese?
Common errors include over‑cooking the pasta before smoking, which leads to mushy noodles, and under‑seasoning the roux, resulting in a bland sauce. Also, opening the smoker too often can cause temperature fluctuations and a weak smoke flavor.
Why does this recipe use a cast‑iron skillet for smoking instead of a baking dish?
A cast‑iron skillet conducts heat evenly and can go directly from stovetop to smoker, eliminating the need for an extra dish. Its heavy walls help develop a crisp, golden crust while retaining the creamy interior.
Can I make smoked mac and cheese ahead of time and how should I store it?
Yes. Prepare the cheese sauce and cook the pasta up to step 6, then refrigerate the assembled skillet uncovered for up to 24 hours. When ready, add the topping and smoke as directed. Leftovers keep 3 days in the fridge or 2 months frozen.
What texture and appearance should I look for when the smoked mac and cheese is done?
The top should be a deep golden‑brown crust with a buttery, crunchy panko layer. The interior should be bubbling, creamy, and the noodles should still have a slight bite, indicating they weren’t over‑cooked in the smoker.
How do I know when the smoked mac and cheese is done cooking?
After the 1‑hour smoke, the crust will be firmly set and the edges slightly crisp. Insert a fork; it should glide through the noodles with little resistance, and the cheese should be fully melted with no visible liquid pooling.
What does the YouTube channel Hey Grill Hey specialize in?
The YouTube channel Hey Grill Hey, hosted by Susie Bulloch, specializes in outdoor grilling, smoking, and backyard barbecue techniques, offering step‑by‑step tutorials for classic and inventive BBQ dishes.
How does the YouTube channel Hey Grill Hey's approach to American barbecue differ from other cooking channels?
Hey Grill Hey focuses on practical, equipment‑light methods that blend traditional grilling with modern smoking, often using everyday kitchen tools like cast‑iron skillets. The channel emphasizes flavor layering with wood smoke and simple rubs, setting it apart from channels that rely on high‑tech gadgets.
Last updated: August 31, 2026
