Awesome Smoked Mac and Cheese

Ingredients

• 1 pound Elbow Macaroni (dry pasta; can substitute penne, shells, or other short pasta)
• 1 tablespoon Olive Oil (extra virgin, drizzled over cooked pasta to prevent sticking)
• 1 stick Unsalted Butter (cut into cubes; used for roux and topping)
• 0.33 cup All-Purpose Flour (sifted before adding to butter)
• 0.5 tablespoon Dry Mustard (ground mustard powder for subtle tang)
• 1 tablespoon Kosher Salt (adjust to taste)
• 1 teaspoon Black Pepper (freshly ground)
• 4 cups Whole Milk (2% or whole for richness)
• 8 ounces Gruyère Cheese (shredded from a block; adds nutty flavor)
• 18 ounces Sharp Cheddar Cheese (16 oz for sauce, 2 oz reserved for topping; shredded from a block)
• 0.5 cup Panko Breadcrumbs (Japanese style, larger flakes for crisp topping)
• 2 tablespoons Butter (for topping) (adds richness to toasted panko)
• 1 tablespoon Barbecue Rub (Three Little Pigs Kansas City Championship rub preferred)
• 4 pieces Apple Wood Chunks (for smoke; can substitute any fruit wood, hickory, or mesquite for stronger flavor)

Instructions

1. Preheat the Pellet Grill

   Fill the pellet hopper with knotty wood plum pellets, start the grill, run the startup cycle, and set the temperature to 270°F.

   Time: PT10M

   Temperature: 270°F

2. Cook the Pasta

   Bring a large pot of salted water to a boil, add 1 lb elbow macaroni and cook for about 5 minutes until al dente (still firm). Drain and return to the pot.

   Time: PT5M

3. Prevent Pasta Sticking

   Drizzle 1 Tbsp olive oil over the drained macaroni and toss to coat evenly.

   Time: PT2M

4. Shred the Cheeses

   Using a rotary cheese grater, shred 8 oz Gruyère and 16 oz sharp cheddar (reserve 2 oz for topping).

   Time: PT5M

5. Make the Roux

   Melt 1 stick (½ cup) unsalted butter in a saucepan over medium heat. Whisk in 1/3 cup all‑purpose flour and cook, whisking constantly, for 3–4 minutes until the mixture is lightly golden and the raw flour taste is gone.

   Time: PT4M

   Temperature: medium

6. Create the Béchamel

   Add ½ Tbsp dry mustard, 1 Tbsp kosher salt, and 1 tsp freshly ground black pepper to the roux. Slowly pour in 4 cups whole milk, a little at a time, whisking continuously. Bring to a simmer over medium‑high heat and cook, whisking, for 8–10 minutes until thickened and smooth.

   Time: PT12M

   Temperature: medium‑high

7. Incorporate the Cheese

   Remove the saucepan from heat. Add the shredded Gruyère and cheddar a handful at a time, stirring until each addition is fully melted before adding more. Continue until all cheese is incorporated and the sauce is glossy.

   Time: PT5M

8. Combine Pasta and Sauce

   Pour the cheese sauce over the oiled macaroni in the large pot, stir to coat evenly, then transfer the mixture to the 12‑inch cast‑iron skillet.

   Time: PT3M

9. First Smoke Phase

   Place the skillet directly on the grill grates, close the lid, and smoke for 30 minutes. Stir the mac and cheese halfway through to expose interior to smoke and prevent a dry crust.

   Time: PT30M

   Temperature: 270°F

10. Prepare the Panko Topping

    In a small skillet, melt 2 Tbsp butter over medium heat. Add ½ cup panko breadcrumbs and toast, stirring, until golden brown (about 2 minutes). Remove from heat and stir in 1 Tbsp barbecue rub.

    Time: PT5M

    Temperature: medium

11. Second Smoke Phase & Finish

    Sprinkle the reserved 2 oz shredded cheddar and the toasted panko mixture over the top of the mac and cheese. Return the skillet to the grill and smoke for an additional 30 minutes, or until the internal temperature reaches 170‑180°F.

    Time: PT30M

    Temperature: 270°F

12. Rest and Serve

    Remove the skillet from the grill, let the mac and cheese rest for 5 minutes to set, then serve directly from the cast iron.

    Time: PT5M

Nutrition Facts

Calories

1150

Protein

45 g

Carbohydrates

100 g

Fat

70 g

Fiber

3 g

Ingredient Substitutions

• Instead of Elbow Macaroni: Penne, Shells, Fusilli
• Instead of Olive Oil: Vegetable oil, Canola oil
• Instead of Unsalted Butter: Margarine, Ghee
• Instead of All-Purpose Flour: Whole wheat flour (will affect flavor)
• Instead of Dry Mustard: Prepared mustard (use less)
• Instead of Kosher Salt: Sea salt
• Instead of Black Pepper: White pepper
• Instead of Whole Milk: Half‑and‑half (richer), Milk alternative (may affect texture)
• Instead of Gruyère Cheese: Emmental, Swiss cheese
• Instead of Sharp Cheddar Cheese: Aged cheddar, Monterey Jack
• Instead of Panko Breadcrumbs: Regular breadcrumbs, crushed cornflakes
• Instead of Butter (for topping): Margarine
• Instead of Barbecue Rub: Any Kansas City style rub, smoked paprika + brown sugar
• Instead of Apple Wood Chunks: Hickory chunks, Mesquite chunks, Cherry wood

Equipment Needed

• Pellet Grill
• Firebox (optional) (optional)
• 12‑inch Cast Iron Skillet
• Large Pot
• Colander
• Rotary Cheese Grater
• Whisk
• Spatula or Wooden Spoon
• Instant‑Read Thermometer
• Measuring Cups and Spoons
• Tongs (optional)
• Baking Sheet (optional for panko) (optional)

Critical Steps — Do Not Skip

• Undercook the pasta so it finishes cooking in the smoker.
• Cook the roux for a full 3‑4 minutes to eliminate raw flour taste.
• Whisk milk in gradually and simmer the béchamel until thick and smooth.
• Add cheese off the heat in small batches to keep the sauce glossy.
• Stir the mac and cheese halfway through the first smoke to allow smoke penetration.

Chef Tips from the Video

• Apple wood gives a subtle sweet smoke; for a bolder flavor use hickory or mesquite.
• Keep the grill lid closed as much as possible to maintain steady temperature and smoke density.
• A thin layer of olive oil on the pasta prevents clumping during the smoking process.

Troubleshooting

Storage

Refrigerator: Cool to room temperature, then store in an airtight container for up to 3 days.

Freezer: Not recommended; texture may become grainy after freezing and reheating.

Room temperature: Can sit out for up to 2 hours after cooking; keep covered.

Make-Ahead Tips

• Prepare the béchamel sauce up to step 7, let it cool, then refrigerate for up to 24 hours. Reheat gently before mixing with pasta.
• Cook the pasta al dente and toss with olive oil; store in the fridge and assemble just before smoking.
• Toast the panko topping ahead of time and keep it in a sealed bag; add during the final smoke.

Frequently Asked Questions