Ultimate Chili Cheese Mac

For the Chili (or use your favorite chili recipe or leftover chili)

• 1 teaspoon plus 1 tablespoon olive oil
• 1 pound ground beef (preferably 85/15)
• One (7-ounce) can chipotles en adobo (smoked jalapeños in adobo sauce)
• 2 garlic cloves, coarsely chopped
• 3 tablespoons chili powder
• 1 tablespoon ancho chili powder
• 1 tablespoon ground cumin
• 1 teaspoon smoked paprika
• 1 to 2 fresh jalapeno chiles, seeded and coarsely chopped
• 1 to 2 teaspoons hot pepper sauce
• 2 cups vegetable stock
• 1 (7 oz) red bell pepper, seeded and cut into 1/4-inch (6-mm) dice
• 1 (7 oz) green bell pepper, seeded and cut into 1/4-inch (6-mm) dice
• 1/2 to 1 Anaheim chile, seeded and cut into 1/4-inch (6-mm) dice
• 1 medium yellow onion, cut into 1/4-inch (6-mm) dice
• 1 medium carrot, peeled and cut into 1/4-inch (6-mm) dice
• One (14.5-ounce) can kidney beans, drained and rinsed
• One (14.5-ounce) can black beans, drained and rinsed
• One (14.5-ounce) can pinto beans, drained and rinsed
• One (14-ounce) can chopped fire-roasted tomatoes with its juice
• One (14.5-ounce) can tomato sauce
• 2 teaspoons kosher salt
• 1 teaspoon freshly ground black pepper

For the Chili Mac

• 4 ounces elbow, spiral, or other short pasta of your choice
• 2 1/2 tablespoons all-purpose flour
• 1/2 teaspoon dry mustard powder
• 1/4 teaspoon garlic powder
• 1/4 teaspoon freshly ground black pepper
• 1/8 teaspoon cayenne pepper, or more if you like an extra kick
• 3 tablespoons salted butter, at room temperature
• 3/4 cup whole milk
• 1/2 cup heavy cream (or substitute 1 1/4 cups or 300 ml half-and-half for the milk and cream)
• 6 ounces mild, medium, or sharp Cheddar cheese, shredded
• 4 ounces Monterey Jack cheese, shredded
• 1 thick slice bread, torn into pieces, or 1/2 cup (35 grams) panko
• 3 cups chili

Make the Chili (or use your favorite chili recipe or leftover chili)

• Heat 1 teaspoon of olive oil in a large skillet over medium heat. Add the ground beef and cook, stirring with a wooden spoon and breaking up any large chunks, until nicely browned and no pink spots remain, about 5 minutes. Drain and discard any excess fat and juices from the skillet.
• In a blender, combine the garlic, chili powder, ancho chile powder, cumin, smoked paprika, jalapeños, hot sauce, 1/2 cup (120 ml) vegetable stock, and as much of the chipotles en adobo as your desired heat level dictates (we recommend starting with 1/2 the can for a moderate spice). Blend on low speed until a smooth purée forms.
• Heat 1 tablespoon olive oil in a large saucepan over medium heat until hot but not smoking. Add both bell peppers, the Anaheim chile, onion, and carrot. Cook, stirring often, until the vegetables have softened and the onion becomes translucent, about 8 minutes.
• Add the garlic and chile purée to the pan and stir to combine thoroughly. Stir in the beans, cooked ground beef, chopped tomatoes with their juices, tomato sauce, 1 1/2 cups (360 ml) vegetable stock, salt, and black pepper. Stir well. Increase the heat to bring the mixture to a gentle simmer. Taste and adjust seasoning; if you prefer a spicier chili, add more hot sauce and/or the remaining chipotles en adobo (mashed with a fork or finely chopped in a food processor). Partially cover and simmer very gently, stirring occasionally, until the vegetables are very soft, 20 to 30 minutes.
• Reserve 3 cups of this delicious chili for your Chili Mac. The remaining chili can be enjoyed immediately with your favorite toppings or portioned into 3-cup servings and frozen for future Chili Mac cravings or quick weeknight meals.

Assemble the Chili Mac Casserole

• Preheat your oven to 400°F (200°C). If your oven has a convection setting, enable it for an even crispier top. Lightly butter an 8-inch (20-cm) glass or metal baking dish.
• Bring a medium saucepan of generously salted water to a rolling boil. Add your chosen pasta and stir immediately to prevent sticking. Boil the pasta, stirring occasionally, until it is just al dente—meaning it still has a slight bite. Cooking times vary by pasta shape, so consult your package directions for guidance and aim to slightly undercook it. Drain the pasta thoroughly in a colander.
• While the pasta is cooking, in a small bowl, whisk together the all-purpose flour, dry mustard powder, garlic powder, black pepper, and cayenne pepper. Set this mixture aside.
• Place the empty pasta pan (no need to wash it!) over medium-low heat and add the butter. Once the butter is melted, whisk in the prepared flour mixture. Cook, whisking almost constantly, for about 30 seconds, until the mixture begins to brown slightly and develops a pleasant, nutty aroma. Be vigilant to prevent it from scorching or burning.
• Gradually whisk the whole milk and heavy cream into the butter-flour mixture, ensuring it is well combined and smooth. Continue to cook, still whisking constantly, until the sauce is fully heated through and just begins to thicken, which should take about 2 minutes. Remove the pan from the heat.
• Add 4 ounces (115 grams) of the shredded Cheddar cheese and all of the Monterey Jack cheese to the sauce. Add the cheese gradually while stirring continuously in one direction with a wooden spoon or rubber spatula until all the cheese has melted smoothly into the sauce. Then, stir in the cooked pasta until every noodle is coated.
• If using fresh bread, tear one thick slice into pieces and pulse in a food processor until fine bread crumbs form, or chop finely by hand. In a small bowl, toss these bread crumbs (or panko) with the remaining 2 ounces (55 grams) of shredded Cheddar cheese. This mixture will form your delightful crispy topping.
• If you’re baking the chili mac right away: Gently rewarm the reserved 3 cups of chili in a small saucepan over medium-low heat until it’s hot and simmering. Pour the hot chili into your prepared baking dish and spread it evenly across the bottom. If your chili seems too liquidy, you may wish to spoon off some of the excess liquid. Carefully spoon the mac ‘n’ cheese mixture over the chili, spreading it out to form an even layer. Finally, sprinkle the bread crumb and cheese topping evenly over the macaroni and cheese.

  If you’re making the chili mac ahead of time: Pour the completely cooled chili into the prepared baking dish and spread evenly. Carefully spoon the mac ‘n’ cheese mixture over the chili and sprinkle evenly with the bread crumb mixture. Cover the dish tightly with aluminum foil and refrigerate for up to 2 days.

• Bake the chili mac, uncovered, until the topping is beautifully toasted and crunchy, and the chili and cheese sauce are bubbling around the edges. This typically takes about 20 minutes. (If you’re baking a refrigerated dish, you may need to add an additional 10 to 15 minutes to the baking time to ensure it heats through.) Let the chili mac cool for approximately 10 minutes before serving. This brief resting period allows the casserole to set, making it easier to scoop and ensuring a more enjoyable texture.
• Generously scoop the warm Chili Mac and Cheese into individual bowls and serve immediately. Garnish with your favorite chili toppings such as sour cream, fresh cilantro, or extra shredded cheese if desired. Enjoy this ultimate comfort food!

Adapted From

Grilled Cheese Kitchen

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