Smoked Mac and Cheese: The Side Dish That Steals the Show

TL;DR: Make a three-cheese sauce on the stove (cheddar, gouda, cream cheese), combine with cooked elbow macaroni, transfer to a cast iron skillet or aluminum pan, and smoke at 225-250F for about 90 minutes until bubbly with a golden top. The smoker adds a subtle layer of flavor that makes this the most requested side dish at every cookout.

Tested 12+ times in our test kitchen. Cook time: about 2 hours total (25 min prep + 90 min smoke). Feeds: 10-12.

Every serious BBQ spread needs a side dish that makes people forget about the main course for a second. This smoked mac and cheese is that dish. We have watched people bypass brisket to get a second helping of this stuff, and it has been the number one requested recipe from friends and family after every cookout we have hosted.

The concept is simple: make a from-scratch mac and cheese (not the boxed stuff, though we respect the boxed stuff), then finish it on the smoker instead of in the oven. The smoke does not overpower the cheese — it adds a subtle, almost mysterious layer that makes people say “what is in this?” without being able to pinpoint it. The top gets a slightly golden, firm crust from the smoke and heat while the inside stays creamy and molten.

The best part? You are already running the smoker for your main course. This just rides along. Put it on 90 minutes before you plan to eat, and it will be ready when you pull the protein.

Ingredients

For the cheese sauce:

4 tablespoons butter (unsalted)
1/4 cup all-purpose flour
3 cups whole milk (do not use skim — you need the fat for a creamy sauce)
8 oz sharp cheddar cheese, shredded (about 2 cups)
4 oz smoked gouda, shredded (about 1 cup)
4 oz cream cheese, cubed
1 teaspoon kosher salt
1/2 teaspoon black pepper
1/2 teaspoon garlic powder
1/4 teaspoon mustard powder
Pinch of cayenne pepper

For the mac:

1 lb elbow macaroni (or cavatappi, shells, or any short pasta that holds sauce)
1 tablespoon kosher salt (for the pasta water)

For the topping:

1/2 cup panko breadcrumbs
2 tablespoons melted butter
1/4 cup shredded sharp cheddar
1/4 cup shredded parmesan
Pinch of paprika

Wood: Hickory, cherry, or pecan. Use whatever wood you are already running for your main cook. The mac and cheese picks up smoke quickly, so it does not need anything specific.

Step-by-Step Instructions

1. Cook the Pasta (10 Minutes)

Bring a large pot of water to a boil. Add 1 tablespoon of salt. Cook the elbow macaroni for 2 minutes less than the package directions (it will continue cooking on the smoker). You want it slightly underdone — al dente with a bit of resistance in the center when you bite it.

Drain and rinse briefly with cool water to stop the cooking. Toss with a tiny drizzle of olive oil to prevent sticking. Set aside.

2. Make the Cheese Sauce (15 Minutes)

Melt 4 tablespoons of butter in a large saucepan over medium heat.

Add the flour and whisk constantly for 1-2 minutes until it forms a smooth paste (roux) that smells slightly nutty. Do not let it brown.

Slowly pour in the milk while whisking constantly. Add it in a thin stream — if you dump it all in at once, you will get lumps. Keep whisking until the mixture thickens and coats the back of a spoon, about 4-5 minutes.

Remove from heat. Stir in the sharp cheddar, smoked gouda, and cream cheese in three additions, stirring until each addition is fully melted before adding the next. The residual heat will melt the cheese smoothly.

Add the salt, pepper, garlic powder, mustard powder, and cayenne. Stir to combine. Taste and adjust seasoning — it should taste slightly saltier than you want because the pasta will absorb some of the seasoning.

3. Combine and Transfer

Fold the cooked pasta into the cheese sauce until every piece is evenly coated.

Transfer to a cast iron skillet (12-inch) or a disposable aluminum pan (9x13). A cast iron skillet gives you a better crust on the edges, but a foil pan works fine and is easier to clean.

Make the topping: Mix the panko breadcrumbs with melted butter, shredded cheddar, parmesan, and a pinch of paprika. Scatter evenly over the top of the mac and cheese.

4. Smoke It (75-90 Minutes)

Place the skillet or pan on the smoker at 225-250F. If you are already running the smoker for a pulled pork or brisket cook, just find a spot for the mac and cheese on the grate.

Smoke uncovered for 75-90 minutes until:

The edges are bubbling
The top is golden brown
The breadcrumb topping is crispy and golden
The whole thing smells incredible

Do not stir during smoking. You want the top to form a crust and the smoke to settle on the surface. Stirring disrupts both.

If the top is getting too dark before the edges are bubbling (which can happen at higher temps), tent loosely with foil for the last 20-30 minutes.

5. Rest and Serve

Pull the mac and cheese off the smoker and let it rest for 10-15 minutes. It will be volcanically hot in the center. The rest also lets the sauce thicken slightly as it cools, giving you a creamier consistency that stays on a plate instead of running everywhere.

Serve directly from the skillet if using cast iron — it looks great on the table and keeps the mac warm for a long time.

Pro Tips

Shred your own cheese. Pre-shredded cheese is coated with anti-caking agents (usually cellulose) that prevent it from melting smoothly. Take the extra 5 minutes to shred block cheese. The sauce will be noticeably creamier.
Smoked gouda is the secret ingredient. It adds a subtle smokiness to the sauce before the mac even touches the smoker. If you cannot find smoked gouda, regular gouda works, but the smoked version is worth seeking out.
Undercook your pasta. This is critical. The pasta will absorb liquid and continue cooking for 90 minutes on the smoker. If it is fully cooked when you combine it with the sauce, it will be mushy by the time you eat it. Two minutes less than package time is the sweet spot.
Make it ahead. Assemble the mac and cheese up to 24 hours in advance and refrigerate. Add the breadcrumb topping right before it goes on the smoker. You may need an extra 15-20 minutes of cook time since it is starting from cold.
Add mix-ins if you want. Diced jalapeños, crumbled bacon, pulled pork, or diced green chiles all work great stirred in before smoking. But honestly, the three-cheese base is perfect on its own.

Frequently Asked Questions

What cheese is best for smoked mac and cheese?

A blend of sharp cheddar (for flavor), smoked gouda (for creaminess and smokiness), and cream cheese (for body) is our favorite combination. You can substitute gruyere, fontina, or pepper jack for the gouda. The key is using at least one sharp cheese for flavor and one melting cheese for texture.

Can I make smoked mac and cheese on a gas grill?

Yes. Set up your gas grill for indirect heat at 250F and add a foil pouch of wood chips over a lit burner. Place the mac and cheese on the unlit side. It will get less smoke than a dedicated smoker, but it still works.

How do I reheat smoked mac and cheese?

Add a splash of milk (2-3 tablespoons), cover with foil, and reheat in a 325F oven for 20-30 minutes until hot and bubbly. Microwave works in a pinch but tends to dry it out. Do not reheat on the smoker — it will pick up too much smoke flavor and the pasta may get overcooked.

Why is my mac and cheese sauce grainy?

The most common causes are adding cheese to boiling sauce (always remove from heat first), using pre-shredded cheese (the anti-caking agents interfere with melting), or using too high heat when making the roux. Low and slow works for cheese sauce just like it works for smoking.

Can I use a different pasta shape?

Absolutely. Cavatappi, shells, penne, and rotini all work well because their shapes hold sauce. Avoid long pastas like spaghetti or linguine — they do not capture enough cheese sauce in each bite.

How much smoke flavor will it pick up?

A subtle, pleasant smokiness — not overpowering. After 90 minutes at 225-250F, the smoke flavor is present but complementary. If you want more smoke, use a heavier smoking wood like hickory. If you want less, use a mild fruit wood like apple.