- Prepare the Ingredients
Gather all ingredients: 1 lb elbow macaroni, ¼ cup unsalted butter, ¼ cup all-purpose flour, 3 cups whole milk, 1 cup heavy cream, 3 cups shredded sharp cheddar, 1 cup shredded Gruyère, 4 oz cream cheese (cubed), 1 tbsp Dijon mustard, 1 tsp Worcestershire sauce, ½ tsp garlic powder, ½ tsp onion powder, ¼ tsp cayenne pepper, 1 tsp salt, and ½ tsp black pepper. Also, soak 2 cups of wood chips in water for at least 30 minutes. Cook the macaroni in salted boiling water for 2 minutes less than the package directs for al dente. Drain and set aside.
- Make the Cheese Sauce
In a large, heavy-bottomed pot or Dutch oven, melt the butter over medium heat. Whisk in the flour and cook for 2 minutes until golden and fragrant, creating a roux. Slowly pour in the milk and cream while whisking constantly to prevent lumps. Bring the mixture to a gentle simmer, stirring frequently, until it thickens enough to coat the back of a spoon, about 5-7 minutes. Remove from heat.
- Combine and Assemble
Off the heat, stir the cubed cream cheese into the hot sauce until smooth. Then, add the shredded cheddar and Gruyère, one handful at a time, stirring until fully melted before adding more. Stir in the Dijon mustard, Worcestershire sauce, garlic powder, onion powder, cayenne, salt, and black pepper. Taste and adjust seasoning. Fold in the drained, cooked macaroni until every piece is coated in the silky sauce.
- Smoke the Mac and Cheese
Preheat your smoker or grill to 225°F using indirect heat. Add your drained wood chips to the coals or chip box. Transfer the mac and cheese mixture to a large cast iron skillet or a disposable aluminum pan. Place the pan in the smoker, close the lid, and smoke for 60 minutes, or until the top is lightly golden and the edges are bubbling gently. Avoid opening the lid too often.
- Serve and Enjoy
Carefully remove the pan from the smoker using heatproof gloves. Let the smoked mac and cheese rest for 5-10 minutes before serving; this allows the sauce to set slightly. Serve it directly from the skillet for a rustic presentation, garnished with a sprinkle of fresh parsley or chives if desired. The smoky aroma will be irresistible.
- Calories:620 kcal
- Protein:24 g
- Carbohydrates:48 g
- Sugar:8 g
- Salt:0.9 g
- Energy:2594 kJ
- Fat:36 g
Let’s be honest. Sometimes you crave that blue-box nostalgia, and sometimes you want something that feels like a warm, smoky hug from your grill. That’s what you get with this smoked mac and cheese recipe. It’s the ultimate backyard barbecue side that can easily steal the show from the main event. I used to think a good mac and cheese was all about the cheese blend—and that’s still crucial—but smoking it introduces a whole new dimension of flavor, a whisper of campfire that makes everything feel more special and hearty.
The Story Behind This Smoked Mac and Cheese Recipe
This dish isn’t some newfangled trend. It’s a natural evolution of Southern pitmaster ingenuity. When you’ve got a smoker or grill going low and slow all day for a brisket or ribs, you’ve got a perfect, gently warming oven just begging to be used. Someone, somewhere, had the brilliant idea to slide a pan of creamy macaroni into that smoky chamber, and a legend was born. That simple act of resourcefulness created a side dish with soul.
What Makes This Version Special
The magic here is in the texture. We’re not just baking a finished casserole; we’re slowly cooking the sauce in the smoker, allowing the smoke to kiss every component. The result is a silky-smooth cheese sauce that clings to every noodle, with a flavor that’s deep, complex, and impossible to replicate in a regular oven. It’s hearty without being heavy, and the subtle smokiness adds a layer of sophistication.
Pro-Tip: The Emulsion is Everything
My biggest aha! moment? Don’t let your sauce break! The key is a stable emulsion. Always grate your own cheese from a block—pre-shredded stuff has anti-caking agents that can make your sauce grainy. And add the cheese off the heat, a handful at a time, letting each addition melt fully before adding the next. This patience ensures a velvety, lump-free sauce that will hold up beautifully in the smoker. For more brilliant culinary science, I often turn to the experts at Serious Eats.
Serving and Pairing Ideas
This isn’t just for cookouts. Serve it alongside a simple roast chicken for a comforting weeknight dinner, or as the star of a vegetarian feast with some grilled asparagus. Drink pairing? A crisp, citrusy pale ale cuts through the richness perfectly, or a glass of oaky Chardonnay can complement the smoky notes. For a real showstopper, top individual servings with a sprinkle of crispy, fried onions or buttery breadcrumbs right before serving.
Variations and Substitutions
Want to mix it up? Try using smoked Gouda or sharp cheddar for an even deeper smoke profile. For a spicy kick, stir in a diced chipotle pepper in adobo. Gluten-free? Your favorite gluten-free elbow pasta works just fine—just watch the cook time. Need to go vegetarian? Ensure your Worcestershire sauce is the anchovy-free kind. This dish is wonderfully adaptable.
Make-Ahead and Storage Smarts
You can assemble the cheese sauce and cooked pasta up to a day ahead. Keep them separate in the fridge. When you’re ready, combine them cold, transfer to your smoker-safe dish, and add 10-15 minutes to the smoking time. Leftovers reheat surprisingly well! Add a splash of milk and warm gently in a covered saucepan over low heat, stirring frequently.
Frequently Asked Questions
Can I make this without a smoker?
You can! Bake it in a 350°F oven for 25-30 minutes until bubbly and golden. You’ll miss the smoke flavor, but it will still be delicious. Consider adding a teaspoon of smoked paprika to the sauce.
My sauce seems too thick after smoking. What do I do?
No worries. Stir in a little warm milk or cream, a tablespoon at a time, until it reaches your desired consistency. The pasta continues to absorb liquid as it rests.
So, there you have it. A smoked mac and cheese recipe that’s more than a side—it’s a conversation starter, a comfort food upgrade, and a guaranteed crowd-pleaser. I promise, once you try this method, you’ll never look at that blue box the same way again. Now, fire up that smoker and get cooking! I’d love to hear how yours turns out in the comments below. And if you’re looking for more inspired dishes, browse our recipe collection.
