Side Dishes
Grilled Smoked Mac and Cheese
Take your comfort food to the next level with this Grilled Smoked Mac and Cheese, a smoky, cheesy, flavor-packed twist on the classic dish. Loaded with flame-charred peppers, grilled onion, and smoky ham, this mac and cheese is cooked in a cast iron skillet and finished with wood-fired smoke for irresistible depth. Perfect as a hearty main or a standout side at your next cookout, this recipe brings bold barbecue flavor to a backyard favorite. Whether you’re firing up a gas, charcoal, or pellet grill, this dish is your new go-to for crowd-pleasing, smoky indulgence.
Grilled Mac and Cheese Recipe
Grilled Smoked Mac and Cheese
Recipe Notes
- Advance Prep: 30 minutes (Grilling ham/veggies, boiling pasta, chopping, assembling in skillet; can be done ahead)
- Active Prep: 40 minutes (Includes all hands-on time: grilling, chopping, sauce-making, assembling)
- Grill Time: 20–30 minutes (Smoke-roasting on indirect heat)
- Total Time: 1 hour 10 minutes (plus optional chilling time if prepping ahead)
- Yield: Serves 4 as a main dish; 6 to 8 as a side
- Method: Grilling (direct and indirect), Smoke-roasting, Stovetop cooking
- Equipment: Grill (gas, charcoal, or pellet), Cast iron skillet (10-inch)
Ingredients
- 1 medium onion, peeled and quartered
- Extra virgin olive oil
- 1 large poblano pepper
- 1 red bell pepper (or another poblano)
- 1-1/4-inch-thick slice of smoked ham
- 2 cups elbow macaroni (about 8 ounces)
- Salt (kosher or sea)
- 5 tablespoons unsalted butter, divided
- 3 tablespoons unbleached all-purpose white flour
- 2 cups milk or half and half
- 1 tablespoon Dijon mustard
- Freshly ground black pepper
- 2 cups (about 8 ounces) coarsely grated sharp cheddar cheese
- 3/4 cup dried breadcrumbs (preferably homemade)
You’ll also need:
- wooden toothpicks; a 10-inch cast iron skillet, lightly oiled; 2 hardwood chunks or 1-1/2 cups hardwood chips, soaked in water for 30 minutes, then drained
Recipe Steps
1: Set up your grill for direct grilling and heat to high. Brush or scrape the grill grate clean and oil it well.
2: Skewer the onion quarters on toothpicks. Arrange the onion, poblano, bell pepper, and ham slice on the grate. Grill until the veggies and ham are darkly browned on all sides, turning with tongs, 2 to 6 minutes per side. Transfer to a sheet pan and let cool.
3: Un-skewer the onion quarters, discarding the toothpicks, and thinly slice. Scrape any burnt skin off the peppers and cut the pepper itself into macaroni-size slivers, discarding the seeds. Cut the ham into macaroni-size slivers.
4: Bring 8 quarts lightly salted water in a large pot to a rolling boil over high heat. Add the macaroni and cook until al dente, 8 minutes. Drain the macaroni in a large colander, rinse with cold water until cool, and drain again. Toss the macaroni with 1 teaspoon butter to prevent sticking.
5: Melt 3 tablespoons butter in a large heavy saucepan. Whisk in the onion and ham and cook for 1 minute. Stir in the flour and cook until bubbling, 1 minute. Whisk in the milk in a thin stream and boil for 2 minutes: the sauce will thicken. Whisk in the mustard.
6: Stir in the macaroni and mix well. Stir in the grilled peppers, grated cheese, and salt and pepper to taste: the mixture should be highly seasoned. Spoon the mac and cheese mixture into the cast iron skillet. The mac and cheese can be prepared ahead to this stage. Let it cool to room temperature, then refrigerate until cooking.
7: Sprinkle the breadcrumbs over the mac and cheese in a thin layer and dot with the remaining butter.
8: Meanwhile, set up your grill for indirect grilling and heat to medium-high, 400 degrees. Add wood chunks to the coals or place in your gas grill’s smoker box. If using a pellet grill, fuel as per the manufacturer’s instructions.
9: Smoke-roast the mac and cheese until the breadcrumbs are browned and crisp, the mac and cheese mixture is bubbling and heated through, 20 to 30 minutes.
