Saturday afternoon, three o’clock. I’m staring at my pantry trying to figure out what to make for a potluck dinner in exactly three hours, and my brain is completely blank. Then I spot a can of diced tomatoes next to a box of macaroni, and suddenly it hits me. What if I took two of the most comforting foods on the planet and merged them into one glorious dish? That’s how I accidentally stumbled onto this chili mac recipe that’s now requested at every single family gathering. The first time I brought this to a friend’s house, people were literally scraping the bottom of the pot, and someone asked if I’d cater their wedding. I laughed, but honestly, this dish has that kind of power over people.
Why This Chili Mac Works So Well
The genius of this recipe lies in how it respects both components equally. You’re not just dumping macaroni into regular chili and calling it done. Instead, you create a proper homemade chili with deep, slow-cooked flavors, then make an authentic cheese sauce from scratch, and finally marry them together in a way that lets each element shine. When you taste it, you get that rich, spiced chili flavor alongside creamy, tangy cheese sauce coating every piece of pasta. It’s comfort food that actually delivers on both fronts instead of compromising either one.
What I love about making chili mac is the flexibility. Some nights I want more chili, less cheese sauce. Other times I’m craving that mac and cheese experience with just enough chili to make it interesting. You control the ratios based on your mood, and honestly, there’s no wrong answer here.
Gathering Your Ingredients
Before we get cooking, let’s round up everything you need for both the chili and the mac and cheese components.
For the Chili
- One pound ground beef, preferably 80/20 for better flavor
- One small onion, diced fine
- Half cup bell pepper, any color, diced
- Three garlic cloves, minced
- One packet chili seasoning mix, about 1.25 ounces
- One tablespoon tomato paste for depth
- Eight ounces tomato sauce
- One 14.5-ounce can diced tomatoes with their juice
- Half cup chicken or beef broth
- One 15-ounce can kidney beans, drained and rinsed
For the Mac and Cheese
- Two cups elbow macaroni, uncooked
- Two tablespoons butter
- Two tablespoons all-purpose flour
- Half cup heavy cream
- One cup whole milk
- Half teaspoon dry mustard powder
- Quarter teaspoon onion powder
- Salt and pepper to taste
- Half teaspoon hot sauce for depth, not heat
- One and a half cups sharp cheddar cheese, freshly shredded
- Another one and a half cups cheddar for topping before baking
- Fresh parsley for garnish
Making the Chili Base
Start by heating a large Dutch oven or heavy-bottomed pot over medium-high heat. Add your ground beef and diced onion, breaking the meat apart with a wooden spoon as it cooks. Let it really brown, not just turn gray. You want those caramelized bits because they add serious flavor. This takes about six to eight minutes. Once the beef is cooked through, drain off most of the excess grease, leaving maybe a tablespoon behind for flavor.
Toss in your diced bell pepper and minced garlic, stirring them into the hot beef mixture. Cook for about two minutes until the pepper starts softening and your kitchen smells amazing. Now sprinkle in the chili seasoning and add the tomato paste, stirring everything together so the paste coats the meat and vegetables. This step is important because cooking the tomato paste for a minute or two removes that raw, tinny flavor and concentrates its richness.
Pour in the tomato sauce, diced tomatoes with all their juice, and the broth. Stir everything together and bring it to a good boil. Once it’s bubbling, reduce the heat to low and let it simmer gently for about 30 minutes, stirring occasionally. The chili will thicken and the flavors will deepen beautifully. About 10 minutes before you’re ready to combine everything, stir in those drained kidney beans so they can warm through and absorb some of that chili flavor.
Creating the Cheese Sauce
While your chili simmers, cook the macaroni according to package directions until just al dente. Drain it thoroughly and set it aside. In a separate large saucepan, melt the butter over medium heat. Once it’s foamy, whisk in the flour and keep whisking for about a minute until it forms a smooth paste that smells slightly nutty. This is your roux, and it needs to cook out that raw flour taste.
Slowly pour in the heavy cream and milk in small additions, whisking constantly to prevent lumps. Keep adding and whisking until all the liquid is incorporated and smooth. Bring this mixture to a gentle boil, then immediately reduce to a simmer. It should thicken noticeably within a few minutes. Add the mustard powder, onion powder, salt, pepper, and that half teaspoon of hot sauce. The hot sauce doesn’t make it spicy, it just amplifies all the other flavors.
Remove the pan from heat and stir in the one and a half cups of shredded cheddar cheese. Stir until it’s completely melted and silky smooth. Add your drained macaroni and toss everything together until every piece of pasta is coated in that creamy cheese sauce.
Bringing It All Together
Now comes the magical moment. Add your prepared chili directly into the pot with the mac and cheese, or vice versa depending on which pot is larger. Gently fold everything together, being careful not to mash the pasta. You want distinct pieces of macaroni swimming through that rich chili, all bound together with cheese sauce. The color should be this gorgeous reddish-orange, and the smell will make everyone suddenly appear in the kitchen asking when dinner is ready.
Transfer everything to an oven-safe dish if you’re not already using one. Sprinkle that remaining one and a half cups of cheddar cheese evenly across the top. Pop it into a preheated 400°F oven for about five minutes, just until the cheese melts and gets slightly golden in spots. If you want it extra bubbly and browned, hit it with the broiler for a minute or two, but watch it closely.
Pro Tips for Perfect Results
- Always shred cheese from a block rather than buying pre-shredded, it melts infinitely better
- Let the chili simmer the full 30 minutes for maximum flavor development
- Don’t skip draining the kidney beans or your chili will be too watery
- Cook macaroni exactly to al dente since it continues cooking when mixed with hot chili
- Make the roux properly by cooking the flour and butter together before adding liquid
- Use hot sauce in the cheese sauce as a flavor enhancer, not for spice
- Let the finished dish rest for five minutes before serving so it thickens slightly
Creative Variations
Once you master the basic version, these twists keep things interesting without much extra effort.
- Swap kidney beans for black beans or pinto beans based on preference
- Add diced jalapeños to the chili for genuine heat
- Mix Monterey Jack into the cheddar for a different flavor profile
- Stir in a handful of fresh spinach right before baking for hidden greens
- Top with crushed tortilla chips before the final bake for crunch
- Use ground turkey or chicken instead of beef for a lighter version
- Make it vegetarian by omitting meat and doubling the beans
Troubleshooting Common Issues
Even straightforward recipes can go sideways. Here’s how to fix the most frequent problems.
- Chili too thin: Simmer it longer uncovered to evaporate excess liquid, or add another tablespoon of tomato paste
- Cheese sauce grainy: Temperature was too high when you added cheese, always remove from heat first
- Pasta mushy: You overcooked it initially or let the final dish sit too long before serving
- Too spicy: Stir in a bit more cheese sauce or a dollop of sour cream to mellow the heat
- Not enough flavor: Your chili didn’t simmer long enough, or you need more seasoning
- Dry after reheating: Add a splash of milk or broth when warming up leftovers
Smart Substitutions
Sometimes you need to work with what’s already in your pantry, and that’s perfectly fine.
- Replace chili seasoning packet with homemade blend of chili powder, cumin, paprika, garlic powder, and oregano
- Use half and half instead of heavy cream for a lighter cheese sauce
- Substitute any short pasta shape like shells or rotini for elbow macaroni
- Swap ground beef for ground pork, turkey, or plant-based crumbles
- Use whatever color bell pepper you have on hand
- Replace kidney beans with chickpeas for a different texture
- Use vegetable broth instead of chicken or beef broth
Storage and Serving
This chili mac stores beautifully, making it perfect for meal prep or enjoying leftovers throughout the week. Let it cool completely before transferring to airtight containers. Refrigerate for up to three days. The pasta will absorb some liquid as it sits, so add a splash of milk or broth when reheating to loosen the sauce back up. Microwave individual portions in 90-second intervals, stirring between each, or reheat gently on the stovetop over low heat.
You can absolutely freeze this for up to three months. The texture of the pasta changes slightly after freezing, becoming a bit softer, but it’s still delicious. Thaw overnight in the refrigerator before reheating. To serve, garnish with fresh parsley, extra shredded cheese, a dollop of sour cream, or sliced green onions. Cornbread or garlic bread on the side turns this into a complete meal.
Frequently Asked Questions
Can I make chili mac ahead of time?
Absolutely. Make the chili one to two days ahead and store it in the fridge. When ready to serve, prepare the mac and cheese fresh, combine them, and proceed with the baking step. This actually improves the chili flavor as it sits.
Do I have to bake it with cheese on top?
No, the baking step is optional. You can skip it and serve the chili mac straight from the pot with cheese stirred in. Baking just gives you that gorgeous melted cheese topping and slightly crispy edges.
Can I leave out the beans?
Yes, the beans are completely optional. Some people prefer their chili mac without them. Just omit them entirely or substitute with extra vegetables like corn or diced zucchini.
What kind of cheese works best?
Sharp cheddar provides the best flavor, but you can use medium cheddar, a blend with Monterey Jack, or even pepper jack for spice. Always shred from a block rather than buying pre-shredded for superior melting.
How do I prevent the pasta from getting mushy?
Cook your macaroni exactly to al dente, even slightly underdone. It continues cooking when combined with the hot chili and cheese sauce, so starting firmer prevents mushiness.
Can I make this in a slow cooker?
You can make the chili portion in a slow cooker, cooking on low for six to eight hours. Make the mac and cheese separately on the stove, then combine them just before serving. Cooking the entire dish in a slow cooker makes the pasta too soft.
Is this recipe spicy?
The base recipe has mild to moderate spice from the chili seasoning. You control the heat level by choosing mild or spicy chili seasoning and adjusting the hot sauce amount. Add jalapeños or cayenne pepper if you want genuine heat.
Chili Mac
Ingredients
Equipment
Method
- In a large Dutch oven over medium-high heat, cook ground beef and diced onion until beef is browned and cooked through, about 6-8 minutes. Drain excess grease, leaving about 1 tablespoon.
- Add bell pepper and garlic to the pot. Cook for 2 minutes until softened. Stir in chili seasoning and tomato paste, cooking for 1 minute.
- Add tomato sauce, diced tomatoes with juice, and broth. Bring to a boil, then reduce to low and simmer for 30 minutes. Stir in kidney beans during the last 10 minutes.
- Meanwhile, cook macaroni according to package directions until al dente. Drain thoroughly and set aside.
- In a large saucepan, melt butter over medium heat. Whisk in flour and cook for 1 minute. Gradually whisk in heavy cream and milk until smooth.
- Bring sauce to a boil, then reduce to simmer. Add mustard powder, onion powder, salt, pepper, and hot sauce. Remove from heat and stir in 1 1/2 cups cheddar cheese until melted. Add drained macaroni and toss to coat.
- Preheat oven to 400°F. Combine chili and mac and cheese in the larger pot, stirring gently. Transfer to an oven-safe dish if needed.
- Sprinkle remaining 1 1/2 cups cheddar cheese on top. Bake for 5 minutes until cheese is melted and bubbly. Garnish with fresh parsley and serve.
Notes
- Shred cheese from a block for better melting than pre-shredded varieties
- Chili can be made 1-2 days ahead and refrigerated
- Don’t overcook the macaroni as it continues cooking when combined with hot chili
- Beans are optional and can be omitted if preferred
