Quick Recipe Version (TL;DR)
Quick Ingredients
- 1 lb (454 g) elbow macaroni
- 4 tbsp (56 g) unsalted butter
- 1/4 cup (30 g) all-purpose flour
- 3 cups (720 ml) whole milk, warmed
- 1 cup (240 ml) heavy cream, warmed
- 1 1/2 tsp kosher salt, plus more for pasta water
- 1/2 tsp black pepper
- 1 tsp mustard powder
- 1/2 tsp smoked paprika
- 1/8 tsp cayenne (optional)
- 1 lb (454 g) sharp cheddar, shredded
- 8 oz (227 g) mild cheddar, shredded
- 4 oz (113 g) Monterey Jack, shredded
- 1 tbsp (15 ml) Worcestershire sauce
- 1 tbsp (15 ml) hot sauce (optional)
- 1/2 cup (50 g) panko breadcrumbs
- 2 tbsp (28 g) unsalted butter (for crumbs)
- 1 1/2 cups (about 170 g) chopped smoked brisket bark/ends
- 1 tsp brisket rub or BBQ seasoning (optional, for crumbs)
- 2 tbsp chopped chives or parsley (optional, for serving)
Do This
- 1. Heat smoker to 250°F (121°C); set up for indirect heat and clean, light smoke.
- 2. Boil macaroni in salted water until just shy of al dente (about 1 minute less than box). Drain.
- 3. Make a roux (butter + flour), whisk in warm milk and cream; simmer until thickened. Turn off heat and melt in cheeses and seasonings.
- 4. Combine pasta + sauce; spread in a buttered 9×13-inch (23×33 cm) pan.
- 5. Toast panko in butter; mix with chopped brisket bark and a little brisket rub.
- 6. Top mac with brisket crumbs; smoke-bake uncovered at 250°F (121°C) for 45 minutes, then 10 minutes at 325°F (163°C) to crisp.
- 7. Rest 10 minutes; garnish with chives; serve hot.
Why You’ll Love This Recipe
- Smoky comfort food: A gentle kiss of smoke turns classic mac and cheese into true barbecue side-dish magic.
- Creamy, not dry: A milk-and-cream cheddar sauce stays lush even after time in the smoker.
- Brisket bark crunch: Buttered crumbs plus chopped brisket bark add salty, crispy, meaty texture in every bite.
- Feeds a crowd: Big-pan friendly and perfect for cookouts, holidays, and game days.
Grocery List
- Produce: chives or parsley (optional)
- Dairy: unsalted butter (6 tbsp / 84 g total), whole milk (3 cups / 720 ml), heavy cream (1 cup / 240 ml), sharp cheddar (1 lb / 454 g), mild cheddar (8 oz / 227 g), Monterey Jack (4 oz / 113 g)
- Pantry: elbow macaroni (1 lb / 454 g), all-purpose flour (1/4 cup / 30 g), panko breadcrumbs (1/2 cup / 50 g), kosher salt, black pepper, mustard powder, smoked paprika, cayenne (optional), Worcestershire sauce, hot sauce (optional), brisket rub or BBQ seasoning (optional)
- Meat: smoked brisket bark/ends (about 1 1/2 cups chopped / 170 g)
Full Ingredients
For the mac
- 1 lb (454 g) elbow macaroni
- Kosher salt, for pasta water
For the creamy cheddar cheese sauce
- 4 tbsp (56 g) unsalted butter
- 1/4 cup (30 g) all-purpose flour
- 3 cups (720 ml) whole milk, warmed
- 1 cup (240 ml) heavy cream, warmed
- 1 1/2 tsp kosher salt
- 1/2 tsp freshly ground black pepper
- 1 tsp mustard powder
- 1/2 tsp smoked paprika
- 1/8 tsp cayenne pepper (optional)
- 1 tbsp (15 ml) Worcestershire sauce
- 1 tbsp (15 ml) hot sauce (optional, for a gentle background heat)
- 1 lb (454 g) sharp cheddar cheese, shredded (about 4 cups loosely packed)
- 8 oz (227 g) mild cheddar cheese, shredded (about 2 cups loosely packed)
- 4 oz (113 g) Monterey Jack cheese, shredded (about 1 cup loosely packed)
For the brisket crumbs topping
- 2 tbsp (28 g) unsalted butter
- 1/2 cup (50 g) panko breadcrumbs
- 1 tsp brisket rub or BBQ seasoning (optional, especially if your brisket bark is mild)
- 1 1/2 cups chopped smoked brisket bark/ends (about 170 g)
Optional finishing touches
- 2 tbsp chopped chives or parsley
- Freshly ground black pepper, to taste
Step-by-Step Instructions
Step 1: Preheat the smoker for gentle, clean smoke
Preheat your smoker to 250°F (121°C), set up for indirect heat. Use a mild-to-medium wood like oak, pecan, or apple. You want thin, pale smoke (not thick white smoke), which keeps the mac and cheese rich instead of bitter.
Place a drip pan if your smoker setup needs it, and make sure you have room for a 9×13-inch (23×33 cm) baking pan or a 12-inch cast-iron skillet.
Step 2: Cook the pasta just shy of al dente
Bring a large pot of water to a boil and salt it generously (the water should taste pleasantly salty). Add 1 lb (454 g) elbow macaroni and cook until it’s 1 minute less than the package directions (typically about 6–7 minutes).
Drain well. Do not rinse. Set aside while you make the sauce.
Step 3: Make a thick, creamy base (roux + dairy)
In a large saucepan or Dutch oven over medium heat, melt 4 tbsp (56 g) butter. Whisk in 1/4 cup (30 g) flour and cook, whisking constantly, for 1 minute. This cooks out the raw flour taste but keeps the roux light.
Slowly whisk in the warmed 3 cups (720 ml) milk and 1 cup (240 ml) heavy cream. Bring to a gentle simmer, whisking often, and cook for 4–6 minutes until the sauce is thick enough to coat the back of a spoon.
Step 4: Melt in the cheeses for a smooth cheddar sauce
Reduce heat to low (or turn it off if your pan holds heat well). Whisk in 1 1/2 tsp kosher salt, 1/2 tsp black pepper, 1 tsp mustard powder, 1/2 tsp smoked paprika, and 1/8 tsp cayenne (if using). Stir in 1 tbsp Worcestershire sauce and 1 tbsp hot sauce (if using).
Add the shredded cheeses a handful at a time, stirring until melted and smooth before adding more: sharp cheddar, mild cheddar, then Monterey Jack. Keep the heat low to prevent graininess.
Step 5: Assemble the mac and cheese in the pan
Butter a 9×13-inch (23×33 cm) baking pan or lightly grease a 12-inch cast-iron skillet. Add the drained pasta and pour in the cheese sauce. Stir until every noodle is coated.
Spread into an even layer. This helps it bake (and smoke) evenly.
Step 6: Make the buttery brisket crumbs topping
In a skillet over medium heat, melt 2 tbsp (28 g) butter. Add 1/2 cup (50 g) panko and cook, stirring constantly, until the crumbs are light golden, about 2–3 minutes.
Remove from heat and stir in 1 tsp brisket rub (optional) and 1 1/2 cups chopped brisket bark/ends. Sprinkle this mixture evenly over the mac and cheese.
Step 7: Smoke-bake, then briefly crisp the top
Place the pan in the smoker uncovered and smoke-bake at 250°F (121°C) for 45 minutes, until the edges are bubbling and the top looks set.
To really lock in crunch on the crumbs, increase the smoker (or move the pan to a preheated oven) to 325°F (163°C) and bake for 10 minutes, until the topping deepens to golden-brown and the brisket bits on top look slightly crisp.
For food safety and best texture, aim for an internal temperature of at least 165°F (74°C) in the center.
Step 8: Rest, garnish, and serve
Let the mac and cheese rest for 10 minutes before scooping. This short rest helps the sauce thicken slightly so servings hold together (but stay creamy).
Finish with 2 tbsp chopped chives or parsley and a few grinds of black pepper, if you like. Serve hot.
Pro Tips
- Shred your own cheese: Pre-shredded cheese contains anti-caking agents that can make sauces less silky. A box grater gives you the smoothest melt.
- Warm the milk and cream: Adding cold dairy can slow thickening and increase the chance of a slightly grainy sauce.
- Go easy on heavy smoke: Mac and cheese absorbs smoke quickly. Thin, clean smoke for under an hour gives flavor without bitterness.
- Use bark strategically: Bark is intensely seasoned. If your brisket bark is very salty or peppery, skip the extra brisket rub in the crumbs.
- Keep it creamy: Slightly undercooked pasta plus a thick sauce prevents the final dish from drying out during the smoke-bake.
Variations
- Spicy BBQ mac: Add 1 diced jalapeño (seeded) to the butter before whisking in flour, and use 2 tbsp hot sauce.
- Extra smoky cheese blend: Replace 4 oz (113 g) of the Monterey Jack with smoked gouda for a deeper smoke note (still keep most of the cheese cheddar-forward).
- Crunch upgrade: Swap half the panko for crushed butter crackers (same volume) for a more old-school, buttery topping.
Storage & Make-Ahead
Refrigerate: Cool completely, cover, and refrigerate for up to 4 days.
Reheat: For best texture, reheat covered in a 325°F (163°C) oven for 20–25 minutes until hot in the center (add a splash of milk, 1–3 tbsp, around the edges if it looks dry). You can also microwave individual bowls in 45-second bursts, stirring between, with a small splash of milk.
Make-ahead: Assemble the mac and cheese (without the crumb topping), cool, cover, and refrigerate up to 24 hours. Before smoking/baking, let it sit at room temp for 30 minutes, add the brisket crumbs, then proceed. Plan on adding 10–15 minutes to the 250°F (121°C) smoke-bake time if it’s going in cold.
Nutrition (per serving)
Approximate, based on 8 servings: 780 calories, 39 g protein, 45 g fat, 52 g carbohydrates, 2 g fiber, 7 g sugar, 980 mg sodium. Values vary with specific cheeses and how seasoned your brisket bark is.
