Smoked Mac & Cheese Recipe

Ingredients

• 12 oz Elbow Macaroni (dry, about one 12‑oz box)
• 4 Tbsp Unsalted Butter (cut into cubes)
• 2 Tbsp All-Purpose Flour (for roux)
• 2 cups Heavy Cream (full‑fat for richness)
• 1 lb Extra Sharp Cheddar Cheese (shredded)
• 0.5 lb Monterey Jack Cheese (shredded)
• 2 Tbsp Mayonnaise (regular)
• 2 Tbsp Sour Cream (full‑fat)
• 2 Tbsp Frank's RedHot Sauce (or any hot sauce)
• 1 tsp Salt (kosher or table)
• 1 tsp Black Pepper (freshly ground)
• 1 tsp Garlic Powder (optional)
• 8 oz Thin‑Sliced Bacon (one package, cooked crisp)
• 1 cup Panko Breadcrumbs (thin‑sliced)
• 1 bag Pecan Wood Pellets (for smoking)

Instructions

1. Cook the Pasta

   Bring a large pot of salted water to a boil, add the elbow macaroni and cook according to package directions until al dente, about 8‑9 minutes.

   Time: PT10M

   Temperature: boiling

2. Drain Pasta

   Drain the macaroni in a colander and set aside while you make the cheese sauce.

   Time: PT2M

3. Make a Roux

   In a saucepan melt the butter over medium heat, whisk in the flour and cook, stirring constantly, for 2‑3 minutes until lightly golden.

   Time: PT5M

   Temperature: medium heat

4. Add Cream

   Gradually whisk in the heavy cream, continue stirring until the mixture thickens and bubbles gently.

   Time: PT3M

   Temperature: medium heat

5. Melt the Cheeses

   Reduce heat to low and stir in the shredded cheddar and Monterey Jack until completely melted and smooth.

   Time: PT5M

   Temperature: low heat

6. Season the Sauce

   Stir in the hot sauce, mayonnaise, sour cream, salt, pepper and garlic powder. Mix until fully incorporated.

   Time: PT2M

7. Combine Pasta and Sauce

   Add the drained macaroni to the cheese sauce, tossing to coat evenly. The mixture will be very creamy.

   Time: PT3M

8. Cook Bacon

   In a skillet over medium‑high heat cook the bacon strips until crisp, about 8‑10 minutes. Transfer to paper towels to drain.

   Time: PT10M

   Temperature: medium‑high

9. Prepare Bacon‑Panko Topping

   In a food processor pulse the crisp bacon with the panko breadcrumbs until the mixture is coarse‑fine, not powdery.

   Time: PT2M

10. Preheat Pellet Grill

    Load pecan pellets and preheat the pellet grill to 350°F.

    Time: PT10M

    Temperature: 350°F

11. Assemble in Skillet

    Spread the mac and cheese evenly in the cast‑iron skillet, then sprinkle the bacon‑panko mixture over the top, pressing lightly.

    Time: PT5M

12. Smoke the Dish

    Place the skillet directly on the grill grate and smoke uncovered for 1 hour, maintaining 350°F. Do not cover so the smoke can circulate and the crust can form.

    Time: PT1H

    Temperature: 350°F

13. Rest and Serve

    Remove the skillet from the grill, let the mac and cheese rest for 5 minutes before serving to set the crust.

    Time: PT5M

Nutrition Facts

Calories

550

Protein

20g

Carbohydrates

45g

Fat

30g

Fiber

2g

Ingredient Substitutions

• Instead of Elbow Macaroni: corkscrew pasta, penne
• Instead of Unsalted Butter: margarine
• Instead of All-Purpose Flour: whole‑wheat flour
• Instead of Heavy Cream: half‑and‑half, whole milk
• Instead of Extra Sharp Cheddar Cheese: sharp cheddar
• Instead of Monterey Jack Cheese: colby, young cheddar
• Instead of Mayonnaise: Greek yogurt
• Instead of Sour Cream: Greek yogurt
• Instead of Frank's RedHot Sauce: Tabasco, sriracha
• Instead of Thin‑Sliced Bacon: turkey bacon, pancetta
• Instead of Panko Breadcrumbs: regular breadcrumbs
• Instead of Pecan Wood Pellets: hickory pellets, apple pellets

Equipment Needed

• Large Pot
• Colander
• Saucepan
• Whisk
• Mixing Bowl
• Food Processor (optional)
• Cast Iron Skillet
• Pellet Grill
• Tongs
• Spatula
• Measuring Cups
• Measuring Spoons

Critical Steps — Do Not Skip

• Cook the pasta al dente
• Make a smooth roux without lumps
• Melt cheeses fully to avoid grainy sauce
• Cook bacon until crisp
• Maintain grill temperature at 350°F for the full hour
• Allow the dish to rest before serving

Chef Tips from the Video

• Use extra‑sharp cheddar for maximum flavor depth
• Add a pinch of smoked paprika to the cheese sauce for extra smoky nuance
• Pecan pellets give a sweet, nutty smoke that pairs perfectly with cheese

Troubleshooting

Storage

Refrigerator: Store in an airtight container for up to 4 days

Freezer: Can freeze for up to 2 months; thaw and reheat gently

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

Make-Ahead Tips

• Prepare the cheese sauce up to step 6 and refrigerate for up to 12 hours; reheat gently before mixing with pasta
• Cook and crumble the bacon ahead of time and store in the fridge
• Assemble the mac and cheese in the skillet, cover, and refrigerate; smoke when ready

Frequently Asked Questions