Why bake Mac & Cheese inside when you can smoke it outside? This mac and cheese recipe uses the gentle heat of the charcoal grill to infuse rich smoke flavor into a creamy, stable cheese sauce, guaranteeing the most flavorful side dish at any gathering.

Key to Successful Mac & Cheese: The Two-Zone Smoke

The key to preventing a curdled, separated sauce is a stable, indirect temperature and incorporating cream cheese for stability.

Ingredients & Prep

Ingredient	Amount	Notes
Elbow Macaroni	1 lb	Cook 2 minutes less than package directions (al dente).
Salted Butter	1/2 cup (1 stick)	You can use salted butter, but reduce added Kosher salt.
All-Purpose Flour	1/2 cup	For making the roux/thickener.
Half-and-Half	4-5 cups (1 qt)	Best for richness and texture.
Cream Cheese	4 oz (1/2 block)	Essential for sauce stability under heat.
Sharp Cheddar	10-12 oz (shredded)	Buy the block and shred it yourself for better melt.
Monterey Jack/Gruyère	4-6 oz (shredded)	Adds melt and stretch.
Smoked Paprika	1-2 Tbsp	Crucial for the smoky flavor in the sauce.
Dry Mustard Powder	1 tsp	Enhances the cheesy flavor.
Black Pepper	1 tsp	To taste.
Panko Breadcrumbs	1/2 to 3/4 cup	For the crunchy topping.
Optional	2 Tbsp Butter	Melted, for tossing with Panko.

Instructions

1. Cook Pasta & Make the Roux

1. Cook Pasta: Cook the macaroni in salted water until al dente (2 minutes shy of package time). Drain and set aside.
2. Melt Butter: In a large pot (off the heat), melt the butter. Whisk in the flour constantly for 1-2 minutes until a smooth paste (roux) forms.
3. Make Sauce: Slowly whisk the half-and-half into the roux until smooth. Return the pot to medium-low heat and stir until the sauce thickens and gently bubbles.

2. The Cheese Sauce

1. Stabilize: Remove the pot from the heat. Stir in the Cream Cheese until it is completely melted and incorporated.
2. Add Cheese: Gradually stir in the Cheddar and Monterey Jack until the sauce is uniform and smooth.
3. Season: Stir in the Smoked Paprika, Dry Mustard, and Black Pepper. Taste the sauce before adding any additional Kosher salt.

3. Assembly

1. Combine: Stir the al dente pasta into the cheese sauce until fully coated.
2. Topping: Toss the Panko breadcrumbs with melted butter (optional) and sprinkle evenly over the mac and cheese in the aluminum foil pan.

4. Smoke & Bake (Approx. 60–90 Minutes)

1. Grill Setup: Set your Weber Kettle for a Two-Zone Indirect Fire (coals pushed to one side) and stabilize the temperature between $325^\circ \text{F}$ and $350^\circ \text{F}$.
2. Smoke: Place 1-2 chunks of Cherry or Apple wood on the coals. Place the foil pan on the indirect side.
3. Bake: Smoke/bake for $\mathbf{60}$ to $\mathbf{90}$ minutes, or until the edges are bubbling and the topping is golden brown and crispy.
4. Rest & Transport: Remove from the grill and let it rest, uncovered, for 10-15 minutes to allow the sauce to set. Then, wrap tightly for travel.

Serving Suggestions

This smoky mac and cheese is the perfect side for smoked turkey, ham, or ribs. Serve it hot, or enjoy it cold right out of the fridge!