Smoked Mac and Cheese
Creamy, smoky, and topped with a golden buttery crust — this smoked mac and cheese is the ultimate cookout side dish that your crowd will beg you to make every single time.
Let me tell you, the first time I pulled this cast iron skillet off the smoker, the whole backyard went quiet. That golden, crackly breadcrumb top? The smell of cherry wood drifting through the air? Pure magic. This recipe is basically the life of the party.
Table of Contents
Why You’ll Love This Smoked Mac and Cheese
This recipe is just the start of something delicious. Browse the entire collection and discover all the ways you can bring more flavor to your table. Your family will thank you.
This isn’t your average boxed mac situation. We’re talking a velvety homemade cheese sauce made with sharp cheddar and smoked gouda, poured over perfectly cooked elbow macaroni.
Then it all goes into the smoker for an hour, soaking up that gorgeous hardwood flavor. It’s rich, creamy, smoky, and has this dreamy breadcrumb topping that adds just the right crunch.
Whether you’re whipping it up as a Father’s Day side or bringing it to your next summer cookout, this dish always earns a standing ovation. It pairs beautifully with a hearty bacon cheeseburger casserole for a full comfort food spread.
Ingredients You’ll Need
Here’s everything to grab before you fire up the smoker. I’ve grouped it so it’s easy to shop and prep.
| Category | Ingredient | Amount |
|---|---|---|
| Pasta | Elbow macaroni noodles | 1 pound |
| Cheese Sauce | Butter | 1/2 cup |
| Cheese Sauce | All-purpose flour | 4 tablespoons |
| Cheese Sauce | Ground mustard powder | 1 tablespoon |
| Cheese Sauce | Half and half | 2 cups |
| Cheese Sauce | Cream cheese | 4 ounces |
| Cheese Sauce | Sharp cheddar cheese, shredded | 3 cups |
| Cheese Sauce | Smoked gouda cheese, shredded | 1 1/2 cups |
| Breadcrumb Topping | Panko bread crumbs | 1 cup |
| Breadcrumb Topping | Butter, melted | 1/4 cup |
| Breadcrumb Topping | Hey Grill Hey Sweet Rub | 2 tablespoons |
Pro tip on the cheese: Always shred your own. Pre-shredded bags have a coating that can make your sauce grainy instead of silky smooth. Trust me on this one.
How to Make Smoked Mac and Cheese Step by Step
Don’t let the smoker intimidate you here. The hands-on time is mostly just making a killer cheese sauce on the stovetop — the smoker does the rest of the work for you.
Step 1: Cook the Noodles
Bring a big pot of salted water to a boil and cook your elbow macaroni until it’s al dente — meaning it still has a slight bite to it.
Don’t overcook them here! They’re going into the smoker for an hour, so if they’re already mushy before that, you’ll end up with sad, soft noodles. Al dente now = perfect texture later.
Step 2: Preheat the Smoker
Get your smoker running at 225 degrees F using a mild hardwood. Cherry or apple wood are my personal favorites — they add a subtle, slightly sweet smoke that doesn’t overpower the cheese.
Hickory works too if that’s what you’ve got, but go easy. Strong wood + a lot of cheese = can sometimes tip into “too smoky” territory.
Step 3: Build the Roux
Heat a 12-inch cast iron skillet over medium heat and melt your 1/2 cup of butter. Once it’s melted and bubbling, whisk in the flour until you get a smooth, thin paste. Then whisk in the mustard powder.
“The roux is what makes this sauce thick and dreamy — don’t rush it. Give it a solid 60 seconds of cooking before adding the liquid.”
This step is the backbone of the whole dish. A good roux = a creamy, lump-free cheese sauce every single time.
Step 4: Finish the Cheese Sauce
Slowly pour in the half and half while whisking constantly. Bring it up to a gentle boil, then reduce the heat. Add the cream cheese and whisk until it’s completely melted and smooth.
Now for the fun part — add in the sharp cheddar and smoked gouda. Keep stirring until everything is fully melted and you’ve got this gorgeous, velvety cheese sauce that smells absolutely incredible.
This BBQ mac and cheese sauce is so good, you might want to eat it straight from the skillet. No judgment here.
Step 5: Add the Noodles
Turn off the heat and pour in your al dente macaroni noodles. Stir everything together gently until every noodle is coated in that luscious cheese sauce.
Try not to over-stir — you want the noodles coated, not broken down. A few gentle folds and you’re good to go.
Step 6: Make the Breadcrumb Topping
In a small bowl, combine the melted butter, Hey Grill Hey Sweet Rub, and panko breadcrumbs. Mix it up until the crumbs are evenly coated.
Sprinkle this all over the top of your mac and cheese in an even layer. This topping is going to turn into this golden, slightly caramelized crust in the smoker — and it is everything.
Looking for more crowd-pleasing cookout ideas? This goes amazingly well alongside one-pan honey garlic kielbasa and veggies for a full BBQ spread.
Step 7: Smoke It Low and Slow
Place the cast iron skillet into your preheated smoker, close the lid, and let it smoke for 1 hour at 225 degrees F.
If you want a stronger smoke flavor, you can push it to 2 hours. But fair warning — the noodles pick up smoke pretty quickly, so don’t go past 2 hours or it can get overwhelming. One hour usually hits the sweet spot.
Step 8: Serve and Enjoy
Pull the skillet off the smoker and let it sit for just a minute or two. Then serve it up while it’s still warm and the cheese is perfectly melty.
Watch how fast it disappears. Spoiler: very fast.
Expert Tips for the Best BBQ Mac and Cheese
Wood Choice Matters
Stick to mild fruit woods like cherry or apple for a subtle sweetness that complements the cheese without overpowering it. If you love a bolder smoke, try a small amount of hickory or pecan blended with a milder wood.
Cast Iron Is Key
A 12-inch cast iron skillet is the ideal vessel here. It distributes heat evenly on the stovetop for the sauce and holds the heat beautifully in the smoker. Avoid thin aluminum pans — they can cause uneven cooking.
Don’t Skip the Mustard Powder
It sounds weird, but ground mustard powder is a secret weapon in cheese sauces. It doesn’t taste like mustard — it just deepens and brightens the cheesy flavor in a way that’s hard to explain but impossible to miss.
Shred Your Own Cheese
Pre-shredded cheese contains anti-caking agents that can make your sauce gritty or grainy. Grab a block of sharp cheddar and smoked gouda and shred them yourself. It takes five minutes and makes a huge difference.
Variations to Try
Spicy Smoked Mac
Add a diced jalapeno to the cheese sauce or swap some of the gouda for pepper jack. A pinch of cayenne in the roux doesn’t hurt either. This version is killer for heat lovers at any cookout side dish spread.
Pulled Pork Mac and Cheese
Fold in about a cup of leftover pulled pork before adding the breadcrumb topping. It turns this side dish into a full, hearty meal. You could also try it with Chinese pepper steak sliced on top for a fusion twist.
Bacon Mac and Cheese
Crumble cooked bacon directly into the cheese sauce before adding the noodles. Or sprinkle it over the top along with the breadcrumbs. Bacon makes everything better — this is a universal truth.
Lighter Version
Swap the half and half for whole milk and reduce the butter slightly. The sauce will be a bit thinner but still totally delicious. You can also cut back the cheeses by a cup and increase the pasta slightly.
Troubleshooting Common Issues
My Sauce Is Grainy
This usually happens when pre-shredded cheese is used or when the sauce gets too hot before the cheese is added. Keep the heat low when melting the cheese and always shred from a block. Adding the cheese off the heat (after turning the burner off) can also help.
My Mac Is Too Dry After Smoking
The smoker can dry things out a bit over time. If you notice the edges drying before the hour is up, tent the skillet loosely with foil for the last 15-20 minutes. This keeps the moisture locked in.
The Breadcrumbs Aren’t Crisping Up
Make sure the butter-to-panko ratio is right and the crumbs are spread in a thin, even layer. If they’re still soft after an hour, crank the smoker up to 250 F for the last 10 minutes to get that golden crust going.
Storage and Reheating
| Storage Method | Duration | Notes |
|---|---|---|
| Refrigerator (airtight container) | Up to 4 days | Cool completely before storing |
| Freezer (freezer-safe container) | Up to 2 months | Texture may change slightly upon thawing |
How to Reheat
For the best results, reheat in the oven at 325 degrees F, covered with foil, until warmed through (about 20-25 minutes). Remove the foil for the last 5 minutes to re-crisp the breadcrumb topping.
Microwave works in a pinch — add a splash of milk before microwaving to keep it creamy and stir halfway through. The breadcrumbs won’t be crispy, but it’ll still taste great.
No-Waste Kitchen Ideas
Leftover smoked mac and cheese makes an incredible base for a loaded baked potato topping. It also works beautifully stuffed inside a burger bun with a smash patty for the most indulgent lunch ever.
You can also turn leftovers into crispy mac and cheese bites — scoop portions, shape into balls, bread them, and pan-fry until golden. Pair them with some homemade sourdough crackers for a fun appetizer platter.
Nutritional Information
The following is an estimate per serving based on 8 servings total.
| Nutrient | Amount Per Serving (Approx.) |
|---|---|
| Calories | 620 kcal |
| Total Fat | 38g |
| Saturated Fat | 23g |
| Carbohydrates | 48g |
| Protein | 22g |
| Sodium | 710mg |
| Fiber | 2g |
| Sugar | 4g |
Nutritional values are estimates and will vary based on specific brands and portion sizes used.
Frequently Asked Questions
Can I make smoked mac and cheese ahead of time?
Yes! You can make the cheese sauce and cook the noodles a day ahead, then combine them and refrigerate. When you’re ready, add the breadcrumb topping and smoke it straight from the fridge.
Just add an extra 15 minutes to the smoke time since it’ll be starting cold. Perfect for stress-free Father’s Day sides planning.
What kind of smoker works best for this recipe?
Any smoker that can hold a steady 225 degrees F works great — pellet smokers, offset smokers, kamado-style grills, even a kettle grill set up for indirect smoking. The key is consistent low heat and good smoke flow around the skillet.
Can I use a different pasta shape?
Elbow macaroni is classic for a reason, but cavatappi, shells, or rotini all work beautifully. You want a shape that has curves or holes to hold onto that creamy cheese sauce. Avoid long pasta like spaghetti — it won’t work here.
What can I substitute for Hey Grill Hey Sweet Rub?
Any sweet BBQ rub works as a substitute. You can also make a quick homemade version with brown sugar, smoked paprika, garlic powder, onion powder, salt, and a pinch of cayenne. It adds that sweet-savory complexity to the breadcrumb topping.
Can I make this without a smoker?
You can bake it in the oven at 350 degrees F for 25-30 minutes until bubbly and golden on top. To add some smokiness, use all smoked gouda and add a tiny bit of liquid smoke to the sauce.
It won’t be quite the same as true smoked mac and cheese, but it’s still incredibly delicious and works great as a cookout side dish when you’re working with a regular oven.
Ready to Fire Up the Smoker?
This smoked mac and cheese is the kind of recipe that becomes a tradition. Once you make it, your family and friends will request it at every cookout, holiday, and backyard hangout for years to come.
It’s creamy, smoky, a little crispy on top, and completely over-the-top in the best possible way. The perfect Father’s Day side or BBQ mac and cheese showstopper.
Looking for something to wash it all down? Try this refreshing tropical butterfly refresher drink — it’s the perfect cool contrast to all that smoky richness.
Give this recipe a try and let me know how it goes! Drop a comment below with your thoughts, any fun variations you tried, or questions. And if you loved it, please save it to your Pinterest boards so other cookout lovers can find it too. Happy smoking!
Smoked Mac and Cheese
Equipment
- 12-inch cast iron skillet
- Smoker
- Large pot
- Whisk
- Mixing bowl
Ingredients
Pasta
- 1 pound elbow macaroni noodles
Cheese Sauce
- ½ cup butter
- 4 tablespoons all-purpose flour
- 1 tablespoon ground mustard powder
- 2 cups half and half
- 4 ounces cream cheese
- 3 cups sharp cheddar cheese shredded
- 1 ½ cups smoked gouda cheese shredded
Breadcrumb Topping
- 1 cup panko bread crumbs
- ¼ cup butter melted
- 2 tablespoons Hey Grill Hey Sweet Rub
Instructions
- Bring a large pot of salted water to a boil and cook the elbow macaroni until al dente. Drain and set aside.
- Preheat the smoker to 225 degrees F using cherry, apple, or another mild hardwood.
- Heat a 12-inch cast iron skillet over medium heat. Melt the butter, then whisk in the flour and ground mustard powder until smooth. Cook for about 60 seconds.
- Slowly whisk in the half and half and bring to a gentle boil. Reduce the heat and stir in the cream cheese until melted and smooth.
- Add the sharp cheddar and smoked gouda cheese. Stir until fully melted and the sauce is creamy.
- Turn off the heat and gently fold the cooked macaroni into the cheese sauce until evenly coated.
- In a small bowl, mix the melted butter, Hey Grill Hey Sweet Rub, and panko bread crumbs until evenly coated.
- Sprinkle the breadcrumb mixture evenly over the mac and cheese.
- Place the skillet in the smoker and cook for 1 hour at 225 degrees F until smoky, bubbly, and golden on top.
- Remove from the smoker, let cool slightly, and serve warm.
