Name: Ultimate Smoked Mac and Cheese (Sharp Cheddar & Gouda)
Prep time: 15 min
Cook time: 15 min
Total time: 30 min
Cuisine: American BBQ
Ingredients: 1 pound elbow macaroni noodles, cooked according to package instructions; 1/2 cup butter; 4 Tbsp all-purpose flour; 1 Tbsp ground mustard powder; 2 cups half and half; 4 oz cream cheese; 3 cups sharp cheddar cheese, grated; 1 1/2 cups smoked Gouda cheese, grated; 1 cup panko bread crumbs; 1/4 cup butter, melted; 2 Tbsp Hey Grill Hey Sweet Rub (or your favorite dry rub)

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If you think you know mac and cheese, think again. This Smoked Mac and Cheese takes the ultimate comfort food and elevates it with a deep, smoky flavor that is absolutely addictive! It’s creamy, cheesy, perfectly seasoned, and finished with a crunchy, flavorful breadcrumb topping.

A rich, decadent side dish that gets an incredible boost of smoky depth from your favorite wood a true game-changer for backyard BBQs and holidays alike.

Recipe Details

Flavor Profile: Intense and savory, with a strong cheddar and Gouda cheese backbone complemented by a robust smoky flavor from the wood, and a touch of tang from the ground mustard and Sweet Rub.
Textures: Features perfectly cooked macaroni, an incredibly smooth and creamy cheese sauce, and a crispy, seasoned panko breadcrumb topping.
Time Commitment: This recipe requires about 15 minutes of active cooking time for the sauce and noodles, plus 1 to 2 hours of hands-off smoking time.
Difficulty: Easy. If you can make a roux (a simple thickened sauce base), you can make this! The smoker does all the heavy lifting for the flavor infusion.

What You’ll Need

This recipe is constructed in a single, large 12-inch cast iron skillet, which serves as both the cooking and smoking vessel. You will need a smoker preheated to a low temperature to gently infuse the cheese sauce. The main components are the elbow macaroni and a homemade cheese sauce built upon a simple butter and flour roux, featuring a blend of sharp cheddar and creamy smoked Gouda.

Ingredient Notes

Elbow Macaroni Noodles – The classic shape for mac and cheese! Its curves hold the rich cheese sauce perfectly. Ensure you cook them only to (slightly firm) because they will soften further in the smoker.
Half and Half – This provides the ideal richness for the cheese sauce base, sitting perfectly between milk and heavy cream.
Cream Cheese – A critical ingredient for creaminess! It helps stabilize the sauce and adds a subtle tang, ensuring the final product remains smooth and doesn’t break under the heat of the smoker.
Smoked Gouda Cheese – This is essential for the cheese blend. The Gouda melts beautifully and its already-smoked flavor perfectly enhances the smoke infusion from the cooking process.
Hey Grill Hey Sweet Rub – This seasoning is used in the breadcrumb topping. It adds a delicious sweet and savory spice profile to the panko, differentiating this topping from a standard breadcrumb crust.

Add-ins and Substitutions

While this recipe is delicious as is, here are a few ways to customize the flavor:

Spice it Up: Add 1/4 teaspoon of cayenne pepper or a pinch of red pepper flakes into the cheese sauce along with the mustard powder for a subtle kick of heat.
Add a Protein: Stir in 1 cup of crumbled, pre-cooked bacon or 1 cup of pulled pork along with the cooked noodles for a complete meal.
Different Cheese Blend: You can substitute the sharp cheddar with Gruyère or Monterey Jack, but maintain the smoked Gouda for the unique flavor element.
Gluten-Free Option: Use gluten-free elbow macaroni and substitute the all-purpose flour with a gluten-free flour blend for the roux.

Cast-iron skillet filled with creamy smoked macaroni and cheese topped with a golden, crispy breadcrumb crust and sprinkled with fresh herbs. — Smoked Mac and Cheese

How to Make Smoked Mac and Cheese

Achieving the perfect smoky flavor requires quick sauce preparation inside the house, followed by the low-and-slow smoke infusion outside.

Step 1: Cook the Noodles

Bring a large pot of salted water to a boil. Cook the elbow macaroni noodles according to the package instructions, ensuring they are (still firm with some chew and texture). Drain the noodles and set them aside.

Step 2: Preheat the Smoker

While the noodles are cooking, preheat your smoker to 225 degrees F (107°C) using a mild hardwood. Cherry or apple wood are recommended favorites for imparting a pleasant, mild smokiness that doesn’t overwhelm the cheese.

Step 3: Make the Roux and Cheese Sauce

Heat a 12-inch cast iron skillet over medium heat on your stovetop.

Make the Roux: Melt the 1/2 cup of butter and then whisk in the 4 tablespoons of all-purpose flour until a smooth, thin paste forms. Next, whisk in the 1 tablespoon of ground mustard powder.
Finish the Sauce: Carefully pour in the half and half and bring the sauce up to a gentle boil while whisking continuously.
Reduce the heat and whisk in the cream cheese until the sauce is completely smooth.
Lastly, whisk in the cheddar cheese and the smoked Gouda cheese and stir until both are fully melted and the sauce is uniform.

Step 4: Combine and Top

Turn off the heat from the stovetop and pour the cooked macaroni noodles into the skillet with the cheese sauce. Stir gently until all the noodles are coated by the cheese sauce.

Make the Topping: In a small bowl, combine the melted 1/4 cup of butter, the Hey Grill Hey Sweet Rub, and the panko bread crumbs.
Sprinkle the prepared breadcrumb topping evenly over the top of the mac and cheese in the skillet.

Pro Tip: Make sure the cheese sauce is fully smooth before adding the noodles. The constant whisking when adding the half and half and the melting of the cream cheese are essential steps for preventing a gritty or broken sauce texture.

Step 5: Smoke and Enjoy

Smoke: Carefully place the skillet in the preheated smoker (set to 225°F). Close the lid and smoke for 1 hour. You can smoke for up to 2 hours if you want a stronger, more intense smoker flavor, but be aware the noodles will take on quite a bit of smoke fairly quickly.
Enjoy: Remove the Smoked Mac and Cheese from the smoker. Serve it while it is still warm and the cheese is nice and melty.

Recipe Tips

Choose the Right Wood: For cheese, a mild fruit wood like cherry, apple, or peach works best. Avoid heavy woods like hickory or mesquite, especially for the full 2-hour smoke, as they can overpower the delicate cheese flavor.
Use Low Heat: Keep your smoker steady at 225°F. Smoking at too high a temperature will cause the cheese sauce to separate or become oily.
Grate Your Own Cheese: Always grate your cheese fresh from the block. Pre-shredded cheese contains anti-caking agents that can prevent it from melting smoothly, resulting in a slightly grainy sauce.
The Importance of Panko: Panko bread crumbs are much lighter and flakier than traditional bread crumbs, which helps them stay crispy even after being tossed with butter and exposed to the smoker’s heat.

FAQs

Q: Can I make this without a smoker? A: You can make the mac and cheese indoors and bake it in the oven at 350°F (175°C) for 20 minutes, but it will not have the signature smoky flavor. You can try adding a few drops of liquid smoke to the sauce before baking, though it won’t replicate the texture perfectly.

Q: How do I store and reheat leftovers? A: Store leftovers in an airtight container in the refrigerator for up to 3 days. To reheat, add a splash of half and half or milk to the mac and cheese in a pot over low heat, stirring occasionally until creamy and hot.

Q: Why do I need to add cream cheese? A: Cream cheese is a stabilizer. It helps create a silky-smooth sauce that resists breaking or curdling, which is especially important when the dish is exposed to the smoker environment.

Q: Can I use different noodles? A: Yes, spiral or shell-shaped pasta will also work well, as they are good at trapping sauce. Just ensure you cook them to the stage.

Golden, creamy smoked macaroni and cheese in a cast-iron skillet, topped with a crunchy browned breadcrumb crust and sprinkled with fresh herbs, with bold text reading “Smoked Mac and Cheese” across the center. — Smoked Mac and Cheese

Serving Suggestions

Smoked Mac and Cheese is the perfect side dish for any BBQ feast. Pair it with:

Smoked Pulled Chicken or BBQ ribs.
Grilled Corn on the Cob topped with butter and cojita cheese.
Tangy Coleslaw or a fresh, crisp salad with a vinegar-based dressing to cut the richness.
Baked Beans with a smoky, molasses-rich sauce.

Make This Recipe in Advance

You can easily get a head start on this recipe to be ready for smoking:

Noodles: Cook the macaroni, drain, and immediately toss with a small amount of oil to prevent sticking. Store covered in the refrigerator for up to 1 day.
Cheese Grating: All the cheese can be grated and stored in an airtight container in the refrigerator up to 2 days ahead of time.
Full Assembly: You can prepare the mac and cheese completely (through Step 4, including the breadcrumb topping) and store it covered in the cast iron skillet in the refrigerator for up to 1 day. Let it sit at room temperature for 20 minutes before placing it in the smoker to ensure even heating.

Smoked Mac and Cheese

Recipe Details