Smoked Mac ‘n’ Cheese

Get ready for mac ‘n’ cheese that will make your taste buds do a happy dance!

This isn’t your basic stovetop version—we’re taking this comfort food classic to smoky, cheesy heights that’ll have everyone begging for seconds.

The combination of three cheeses plus that irresistible kiss of smoke transforms an everyday dish into something legendary.

What makes this recipe special is the triple threat of aged cheddar, pepper Jack, and Parmesan cheeses, all melted into a velvety sauce that coats every pasta curve.

Then there’s the bacon—crispy, salty bits that add texture and that unmistakable savory punch.

But the real magic happens when it all gets bathed in gentle wood smoke, creating layers of flavor you simply can’t get from an oven.

Ingredients

For the cheese sauce:

• 1/2 pound bacon, chopped
• 1/2 cup butter
• 1/2 onion, finely chopped
• 1 clove garlic, chopped
• 3 tablespoons all-purpose flour
• 3 cups whole milk
• Salt and black pepper, to taste
• 3 cups grated aged cheddar cheese

For the pasta and topping:

• 2 pounds macaroni or your favorite small curly pasta
• 2 cups grated pepper Jack cheese
• 1 cup grated Parmesan cheese

Equipment needed:

• Smoker or grill
• Large baking dish
• Sauté pan
• Large pot for pasta

Steps

1. Line a plate with paper towels. Place the 1/2 pound bacon in a sauté pan, and cook on medium-low heat for 8-10 minutes until crisp but not overcooked. Watch carefully—bacon can go from perfect to burnt quickly. Using a slotted spoon, transfer the bacon bits to the plate to drain. Pour 1 to 2 tablespoons of bacon fat into a clean sauté pan, and reserve the rest for another use. The reserved fat will keep in the refrigerator for up to 1 week.
2. Heat the bacon fat over medium heat. Add the 1/2 cup butter and chopped onions, and cook, stirring often, for 4-5 minutes until the onions are soft but not brown—browning will give a bitter taste. Add the minced garlic and stir for 30 seconds until it releases its fragrance but doesn’t brown. Add the 3 tablespoons flour, stirring continuously with a wooden spoon or whisk until it forms a paste. Cook this roux for 2-3 minutes, stirring constantly to prevent scorching. This cooking time is crucial—too short and your sauce will taste like raw flour, too long and it won’t thicken properly.
3. Slowly add the 3 cups milk to the roux, 1 cup at a time, whisking vigorously after each addition until completely smooth. If lumps form, whisk energetically or use an immersion blender to smooth them out. Bring to a gentle simmer (small bubbles around the edge of the pan) and cook for 3-4 minutes until the sauce coats the back of a spoon. Season to taste with salt and pepper—start with 1/2 teaspoon salt and 1/4 teaspoon pepper. Once the liquid is warm, mix in the 3 cups grated cheddar cheese, stirring until completely melted and smooth. Remove from the heat and cover to keep warm.
4. Bring a large pot with 4-5 quarts of water and 1 tablespoon salt to a rolling boil. Add the 2 pounds macaroni and cook according to package directions, but subtract 1-2 minutes from the cooking time to keep it slightly firm. This undercooking is intentional—the pasta will continue cooking in the cheese sauce and absorb more flavor. Test a piece by biting into it; it should have slight resistance in the center. Drain the pasta thoroughly but don’t rinse—the starch helps the sauce adhere. Mix it into the cheese sauce and stir well to coat every piece.
5. Prepare your smoker or grill for smoking, to medium heat (225-250°F/107-121°C). If using a charcoal grill, set up for indirect heat with coals on one side. For gas grills, turn on only half the burners. Add wood chips according to your smoker’s instructions—hickory or apple wood work beautifully with this dish.
6. Pour half of the mac ‘n’ cheese mixture into a large baking dish. Sprinkle evenly with 1 cup of the pepper Jack cheese, ensuring good coverage. Then cover with the remaining mac ‘n’ cheese. Top with the remaining 1 cup pepper Jack cheese, the 1 cup Parmesan, and all the bacon bits. The layering technique creates pockets of melted cheese throughout the dish rather than just on top.
7. Place the baking dish on the indirect heat side of your grill or in your smoker. Close the lid and smoke for 20-30 minutes until the mixture is bubbly around the edges and the top is slightly browned. The cheese should be completely melted and starting to form a light crust. If using a meat thermometer, the center should reach 165°F (74°C) for food safety.
8. Remove from the heat and allow to cool slightly for 5-10 minutes before serving. This resting time allows the cheese to set slightly so servings hold their shape better. If you can wait that long! Serve this dish family-style directly from the baking dish. The crispy, smoky top layer contrasts beautifully with the creamy interior.

Smart Swaps

• Use whole wheat pasta instead of regular macaroni for added fiber and nutrients
• Substitute smoked Gouda for half the cheddar to intensify the smoky flavor
• Replace 1 cup of milk with evaporated milk for an even creamier texture
• Try panko breadcrumbs mixed with 2 tablespoons melted butter on top for extra crunch

Make It Diabetes-Friendly

• Use high-protein, low-carb pasta (like chickpea or lentil pasta) to reduce carbs by approximately 15g per serving
• Replace 1 cup of the cheese with low-fat versions to reduce fat content without sacrificing creaminess
• Add 1 cup of cauliflower florets, steamed and puréed, to the cheese sauce to reduce carb density while maintaining creamy texture
• Serve in 1/2 cup portions alongside a green salad with vinaigrette to reduce glycemic impact

Pro Tips

• Grate your cheese fresh rather than using pre-shredded—it melts much better without the anti-caking agents
• For extra smoky flavor, add 1/2 teaspoon of smoked paprika to your cheese sauce
• If your cheese sauce seems too thick, add warm milk 1 tablespoon at a time until you reach desired consistency
• For a crispy top, finish under the broiler for 1-2 minutes after smoking—but watch carefully to prevent burning