Chef Tommy Williams - Comfort Food Master
👨‍🍳 Comfort Food Chef

Recipe by Mitchell

🎓 Culinary Arts Graduate ⏰ 20+ Years Experience 🍽️ Comfort Food Specialist

❤️ My Recipe Story

"This recipe was born from my obsession with combining America's favorite flavors into one ultimate dish. After countless experiments, I created this monster casserole that brings together everything we love about BBQ bacon cheeseburgers and creamy mac and cheese."

Tommy specializes in elevated comfort food that brings together classic American flavors. He's dedicated his career to perfecting dishes that satisfy our deepest comfort food cravings while maintaining restaurant-quality execution.

View All Mitchell's Recipes →
Golden-brown BBQ bacon cheeseburger mac and cheese casserole with crispy breadcrumb topping, melted cheese, and bacon pieces in a white baking dish

Building the Ultimate Comfort Casserole

The secret to this incredible casserole lies in balancing the rich cheese sauce with the bold BBQ flavors without overwhelming any single element. The ground beef is seasoned with classic burger seasonings, while the BBQ sauce adds that smoky sweetness that makes this dish irresistible.

Creating the perfect cheese sauce requires patience and proper technique. The combination of sharp cheddar, mozzarella, and Monterey Jack creates complex flavor while ensuring smooth melting. The addition of heavy cream and properly tempered eggs creates the silky, rich texture that coats every piece of pasta.

💡 Professional Tip

Cook the pasta just until al dente since it will continue cooking in the oven. This prevents mushy pasta in the final dish. Also, let the casserole rest for 10 minutes after baking to allow the cheese sauce to set properly.

Frequently Asked Questions

Yes, assemble the casserole up to 24 hours ahead without the breadcrumb topping. Cover and refrigerate. Add topping just before baking and increase baking time by 10-15 minutes.

Elbow macaroni is classic and works perfectly, but cavatappi, shells, or penne also work well. Choose shapes that hold cheese sauce in their curves and ridges.

Absolutely! Try Gouda for smokiness, pepper jack for heat, or Gruyère for sophistication. Just maintain the ratio of good melting cheeses to ensure proper texture.

Keep heat at medium or below when making the roux and adding milk. Temper the eggs properly by adding hot sauce gradually while whisking constantly to prevent curdling.

Yes, freeze assembled but unbaked casserole for up to 3 months. Thaw overnight in refrigerator before baking. Baked casserole can be frozen for up to 2 months but texture may be slightly different.

Use a balanced BBQ sauce that's not too sweet or too smoky. Kansas City style works well, or make your own blend. Avoid sauces with lots of chunks that might interfere with the creamy texture.

The top should be golden brown and the edges should be bubbly. Internal temperature should reach 165°F (74°C). If the top browns too quickly, cover with foil.

This is quite rich, so serve with a fresh green salad, coleslaw, or steamed vegetables. Pickles and sliced tomatoes also help cut through the richness.

Recipe Troubleshooting Guide

✅

Broken Cheese Sauce

Problem: Cheese sauce becomes grainy or separated

Solution: Remove from heat immediately and whisk in a splash of cold milk. Use lower heat next time and add cheese gradually off the heat, whisking constantly.

✅

Dry Casserole

Problem: Finished casserole seems dry or pasta is tough

Solution: Ensure pasta is only cooked to al dente, use enough cheese sauce to coat generously, and don't overbake. Cover with foil if top browns too quickly.

✅

Soggy Topping

Problem: Breadcrumb topping doesn't crisp up

Prevention: Toss breadcrumbs with oil before adding, don't skip the uncovered baking time, and use panko breadcrumbs for better texture. Broil briefly if needed.

✅

Too Salty

Problem: Casserole turns out too salty

Recovery: Bacon and cheese add significant salt, so taste before adding extra salt. Serve with fresh vegetables or add a squeeze of lemon to balance flavors.

✅

Uneven Cooking

Problem: Some areas cook faster than others

Prevention: Spread mixture evenly in dish, ensure oven is properly preheated, and rotate dish halfway through baking. Use proper size baking dish for even depth.

✅

Flavor Balance Issues

Too Sweet: Add more Worcestershire sauce or a pinch of black pepper

Too Salty: Serve with fresh tomato slices or a squeeze of lemon juice

Bland: Increase garlic powder, add more BBQ sauce, or finish with hot sauce

Ingredients for BBQ bacon cheeseburger mac and cheese including pasta, ground beef, bacon, multiple cheeses, and BBQ sauce arranged on a marble counter

Selecting Premium Ingredients

The quality of ingredients makes a significant difference in this rich casserole. Choose 80/20 ground beef for the perfect balance of flavor and moisture. The fat content is essential for creating juicy, flavorful meat that complements rather than competes with the creamy cheese sauce.

Cheese selection is crucial for both flavor and melting properties. Sharp cheddar provides tang and color, mozzarella adds stretch and creaminess, while Monterey Jack contributes mild flavor and smooth melting. Using pre-shredded cheese is convenient, but freshly grated melts more smoothly.

Essential Ingredient Notes

  • Ground Beef Quality: Look for freshly ground beef with good color and marbling. Avoid lean varieties as they'll result in dry, flavorless meat that doesn't complement the rich sauce.
  • Bacon Selection: Choose thick-cut bacon for better texture and flavor. The bacon fat adds tremendous flavor to the beef mixture, so don't skip reserving some for cooking.
  • Cheese Freshness: Grate cheese fresh for smoothest melting. If using pre-shredded, check the date and avoid varieties with too many anti-caking agents that can affect texture.
BBQ bacon cheeseburger mac and cheese being assembled in layers in a baking dish, showing the creamy pasta mixture and cheese sauce

Mastering the Cooking Process

Success with this complex casserole requires careful timing and temperature control. The cheese sauce must be smooth and properly thickened before combining with other elements. Taking time to properly temper the eggs prevents curdling and creates the silky texture that makes this dish restaurant-quality.

The final baking stage brings all elements together while creating the golden, crispy top that provides textural contrast to the creamy interior. Covering initially allows gentle cooking, while the final uncovered time creates the appealing golden surface.

Perfect Cheese Sauce

Make a proper roux by cooking flour and butter together for 2 minutes before adding liquid. This eliminates the raw flour taste and creates a smooth base that won't separate.

BBQ Bacon Cheeseburger Mac n' Cheese Casserole

Prep 30 min
Cook 40 min
Serves 10 servings
Level Intermediate

📋 Ingredients

For the Base

  • 60g butter
    For making the roux base
  • 60ml all-purpose flour
    Thickens the cheese sauce
  • 720ml whole milk
    Creates creamy base
  • 240ml heavy cream
    Adds richness and smoothness
  • 450g sharp cheddar, shredded
    Primary cheese for flavor
  • 225g mozzarella, shredded
    Adds stretch and meltability
  • 115g Monterey Jack, shredded
    Smooth melting cheese

For the Cheese Sauce & Topping

  • 450g elbow macaroni
    Classic shape holds sauce perfectly
  • 900g ground beef (80/20)
    Perfect fat ratio for flavor
  • 340g bacon, chopped
    Thick-cut bacon provides best flavor
  • 1 large onion, diced
    Adds sweetness and depth
  • 120ml BBQ sauce
    Choose balanced, not too sweet sauce
  • 60ml ketchup
    Classic burger flavor
  • 15ml Worcestershire sauce
    Adds umami depth

Instructions

  1. Cook Pasta and Bacon

    Cook macaroni according to package directions until al dente. Drain and set aside. In a large skillet, cook chopped bacon until crispy, about 8-10 minutes. Remove bacon and drain on paper towels, reserve 2 tablespoons bacon fat.

  2. Prepare Beef Mixture

    In the same skillet with bacon fat, cook ground beef over medium-high heat until browned, about 8 minutes. Add onion and garlic, cook until softened, 5 minutes. Stir in BBQ sauce, ketchup, Worcestershire, mustard, and seasonings. Cook 3 minutes more.

  3. Make Cheese Sauce

    In a large saucepan, melt butter over medium heat. Whisk in flour and cook 2 minutes. Gradually add milk and heavy cream, whisking constantly until smooth. Simmer until thickened, about 5 minutes. Remove from heat and stir in 3 cups mixed cheeses until melted.

  4. Combine and Assemble

    Preheat oven to 375°F (190°C). In beaten eggs, temper with small amount of hot cheese sauce, then stir back into sauce. Combine cooked pasta, beef mixture, most of the bacon, and cheese sauce. Transfer to greased 9x13 inch baking dish.

  5. Top and Bake

    Mix panko breadcrumbs with olive oil and remaining cheese. Sprinkle over casserole along with reserved bacon. Bake covered 25 minutes, then uncovered 15 minutes until golden and bubbly. Let rest 10 minutes, garnish with chives before serving.

Recipe Notes & Tips

Storage

Cooked casserole keeps in the refrigerator for up to 4 days. Reheat individual portions in the microwave or reheat the whole dish covered in a 350°F oven until heated through.

Serving Suggestions

This rich casserole pairs best with light, fresh sides like coleslaw, green salad, or steamed broccoli. Pickles and sliced tomatoes help cut through the richness.

Variations

Try adding jalapeños for heat, mushrooms for earthiness, or different BBQ sauce flavors. You can also substitute ground turkey or add diced tomatoes for freshness.