Smoked Mac and Cheese Recipe

This Smoked BBQ Mac and Cheese takes inspiration from Tini’s viral mac and cheese recipe and gives it a backyard barbecue twist with smoky flavor and BBQ-seasoned cheese sauce. Loaded with cheddar, pepper jack, mozzarella, and Colby Jack cheeses, it’s smoked low and slow for the ultimate creamy, cheesy side dish.

If you have seen Tini Younger’s viral mac and cheese floating around your feed, you already know how good that recipe is. This version takes everything that makes it incredible and runs it through the smoker for a deeply savory, extra smoky upgrade that belongs at every BBQ.

The layered cheese pull, the creamy sauce, the cavatappi noodles coated in melted sharp cheddar and mozzarella; it is all here, just with a wood-kissed twist that makes it a serious contender for best smoked mac you have ever had.

Whether you are running a pellet smoker, an electric smoker, or even a charcoal grill set up for indirect heat, this recipe works. It is a great side dish for smoked brisket, pulled pork, or my popular party ribs, but honestly, it could hold its own as the main event.

Why This Recipe Works

• Slightly undercooking the pasta before it hits the smoker means the noodles finish perfectly in the low heat environment without turning mushy.
• A roux-based cheese sauce using evaporated milk and heavy cream creates a stable, creamy sauce that does not break during the longer cook time at 250°F.
• Layering the cheese instead of mixing it all in gives you pockets of melted cheese throughout the entire pan, plus a golden brown top that sets up beautifully.
• Using a mix of sharp cheddar cheese, mozzarella, and Colby Jack gives you the best texture and a well-rounded flavor without any one cheese overpowering the rest.

Ingredients You Will Need

Pasta

• Cavatappi pasta (elbow macaroni works great too as a classic option)

Cheese Mixture

• Mozzarella, shredded (always shred your own cheese if you can — pre-shredded cheese contains starches that can make the sauce grainy)
• Sharp cheddar cheese, shredded
• Colby Jack cheese, shredded
• Pepper Jack cheese, shredded (this is not in Tini’s recipe, but I like a little heat in my mac and think it goes well with the smoke flavor).

A note on cheese: Feel free to mix in a little Gouda cheese or Monterey Jack for a slightly different flavor profile. Both are creamy cheeses that melt well and hold up in a smoker environment. Mild cheddar can substitute for sharp if that is what you have on hand, though sharp gives you more depth.

Cheese Sauce

• Unsalted butter
• All purpose flour
• Evaporated milk
• Heavy cream
• Dijon mustard
• Garlic powder
• Smoked paprika
• Salt and black pepper to taste

Optional Add-ins

• Crispy bacon or crumbled bacon on top adds a great smoky crunch
• A pinch of cayenne pepper if you want a little heat
• Panko breadcrumbs on top for a crispier finish
• A splash of hot sauce stirred into the cheese sauce

Equipment

• Smoker (pellet smoker, electric smoker, charcoal grill set up for indirect heat, or a Weber kettle)
• Disposable aluminum pan or a large cast iron skillet (cast iron pan will retain heat and give you a slightly crispier bottom)
• Wood pellets or wood chips (hickory, applewood, or cherry all work well)

How to Make Smoked Mac and Cheese

Step 1: Cook the Pasta

Bring a large pot of salted water to a boil and cook your cavatappi or elbow macaroni until just shy of al dente, about 1 to 2 minutes less than the package directions. The pasta will continue cooking on the smoker, so pulling it a little early is key. Drain and set aside. Do not rinse the cooked pasta — the starch helps the sauce cling to the noodles.

Step 2: Make the Cheese Sauce

In a large pot or large skillet over medium heat, melt the butter. Whisk in the flour and cook for about 1 minute until the raw flour smell cooks off. This is your roux, and it is what keeps the creamy sauce stable.

Slowly pour in the evaporated milk and heavy cream, whisking constantly until smooth. You do not want lumps here. Keep the heat at medium and let it come together for about 1 to 2 minutes until it thickens slightly.

Stir in the Dijon mustard, garlic powder, smoked paprika, salt, and black pepper. Taste and adjust seasoning. If you want to add onion powder or a little cayenne pepper, this is the moment.

Step 3: Add the Cheese

Reserve about 2 cups of the shredded cheese blend for the top. Over low heat, gradually add the remaining cheese to the warm sauce a handful at a time, stirring between each addition until fully melted. Taking your time here keeps the cheese sauce smooth and silky instead of grainy. Avoid cranking up the heat, as the cheese cooks best low and slow.

Step 4: Combine and Layer

Add the cooked macaroni noodles to the cheese sauce and stir until every piece of pasta is fully coated. Grease your disposable aluminum pan or cast iron pan with cooking spray.

Pour in half the mac and cheese mixture. Sprinkle a layer of the reserved cheese over that. Add the rest of the macaroni and cheese on top, then finish with the remaining cheese so the top of the mac is fully covered.

Step 5: Smoke It

Preheat your smoker to 250°F. Place the pan on the smoker over indirect heat and let it go for about 1 hour. You are looking for a bubbly, golden brown top with the cheese fully set. The longer cook time at a lower temperature compared to a traditional oven bake gives the pasta time to absorb that smoke flavor without drying out.

If you are using a pellet grill like a Traeger, this is a set it and monitor situation. Charcoal grills and a Weber kettle work well too, as long as you have the heat running indirectly and are maintaining a more consistent temperature around 250°F.

Step 6: Rest Before Serving

Let the pan rest for about 10 minutes before digging in. This lets the creamy texture set up slightly so it holds together when you scoop it rather than running across the plate. Worth the wait.

Tips for the Best Smoked Mac and Cheese

Shred your own cheese. Pre-shredded cheese is coated in anti-caking agents that prevent it from melting smoothly into a sauce. Buying blocks and shredding them yourself makes a noticeable difference in the final creamy texture.

Do not skip the rest time. Pulling this straight off the smoker and scooping immediately means you get a looser, soupier consistency. Ten minutes makes a big difference.

Use a disposable pan for easy cleanup. A large disposable aluminum pan is great here, especially if you are making this for a crowd. A large cast iron skillet is a great option if you want slightly crispier edges and a more rustic presentation.

Adjust your smoke level. At 250°F for an hour, you get a solid smoke flavor without it being overwhelming. If you want more smoke, you can go a little longer, but watch for the top drying out. A light wood like applewood keeps the flavor from getting too heavy.

Make it ahead. You can assemble the entire pan the night before, refrigerate it at room temperature covered, and pull it out about 30 minutes before it goes on the smoker. You may need to add an extra 10 to 15 minutes of cook time if it is going on cold.

Storage. Leftovers keep well in the fridge for 3 to 4 days. Reheat with a splash of milk stirred in to bring the creamy sauce back. The microwave works, but the oven at low heat is better for keeping the texture intact.

What to Pair With Smoked Mac and Cheese

This is one of those comfort-food sides that fit basically anywhere at a BBQ. It is a perfect side dish for smoked brisket, my favorite smoked party ribs, pulled chicken, or smoked sausage. If you want to round out a full spread, pair it with a simple coleslaw or a green salad to balance out the richness.

It can also hold up as a main dish, especially for a crowd where you need to feed a lot of people without a ton of effort. Crumbled bacon or crispy bacon on top adds a great addition if you want a little extra texture and protein.

More Recipes To Try

Baked Mostaccioli Recipe

French Onion Mac and Cheese

Dill Pickle Pasta Salad

Chimichurri Pasta Salad

Authentic Hawaiian Macaroni Salad