Some afternoons, the kitchen hums with a kind of silence that brings back memories—not the loud, clattering moments of family dinners, but the quiet ones where something simple turns extraordinary.
I was flipping through an old recipe card box—one with curled corners and faded ink—when I stumbled across a handwritten note from my sister-in-law. She had a gift for turning casual cravings into weeknight treasures.
One of her gems? Coney Chili Mac. But I couldn’t leave it alone. That blend of chili spice and cheesy macaroni? It had potential to be more. So I turned it into a casserole. With a browned cheesy top, a saucy beef base, and tender pasta in every bite, it became a dish that felt like a hug on a plate. I’ve made it since on blustery days or whenever the grandkids visit. The smell alone brings them running to the table.
What I love most about this recipe is how it bridges generations—those quick-to-please flavors from the drive-in, married with the comfort of a baked casserole. It’s practical enough for a busy weeknight, hearty enough for a potluck, and warm enough to bring back memories of simpler times.
Short Description
Coney Chili Mac Casserole combines savory ground beef, zesty tomato-chili sauce, and tender macaroni in a cheesy, oven-baked dish that’s quick, comforting, and crowd-pleasing.
Key Ingredients
- 1 lb ground beef
- 2 cups cooked elbow macaroni
- 1 cup tomato sauce
- ½ cup beef broth
- 1 tbsp mustard
- 1 tbsp chili powder
- 1 cup shredded cheddar cheese, divided
- Optional Toppings: diced onions, jalapeños, sour cream or Greek yogurt, crushed tortilla chips
Tools Needed
- Large skillet
- 9×13-inch baking dish
- Mixing spoon or spatula
- Measuring cups and spoons
- Oven
Cooking Instructions
Step 1: Preheat the Oven
Preheat your oven to 350°F (175°C). Lightly grease a 9×13-inch baking dish with cooking spray or a thin layer of butter.
Step 2: Brown the Ground Beef
In a large skillet over medium heat, cook the ground beef. Use a spatula to break it into small crumbles, stirring occasionally until it’s fully browned—about 6–8 minutes. Drain excess fat carefully.
Step 3: Make the Chili Sauce
To the skillet with the beef, add tomato sauce, beef broth, mustard, and chili powder. Stir until evenly combined. Let it simmer over low heat for 5–10 minutes, stirring occasionally, until thickened slightly and aromatic.
Step 4: Combine with Macaroni and Cheese
Turn off the heat. Fold in the cooked macaroni and half of the shredded cheddar cheese. Stir until the mixture is evenly coated and creamy.
Step 5: Transfer to Baking Dish
Spoon the mixture into your prepared baking dish and spread into an even layer. Sprinkle the remaining cheddar cheese across the top.
Step 6: Bake
Bake uncovered in the preheated oven for 20–25 minutes. The casserole should be bubbling at the edges, and the cheese on top should melt into a golden crust.
Step 7: Serve
Let the casserole rest for about 5 minutes before serving. Garnish with your choice of toppings—diced onions, sliced jalapeños, a dollop of Greek yogurt, or crushed tortilla chips for a crunchy finish.
Why You’ll Love This Recipe
– Perfect comfort food with bold, nostalgic flavor
– Great for family dinners, potlucks, or meal prep
– Easy to make with pantry staples
– Customizable toppings for added flavor and fun
– Kid-friendly and freezer-friendly
Mistakes to Avoid & Solutions
Overcooking the pasta: Cook the macaroni until just al dente. Overcooked noodles turn mushy in the oven.
Skipping the simmer step: This lets the chili flavors develop. If you rush it, the sauce will taste flat.
Using too much cheese at once: Save half the cheese for the top to avoid soggy results.
Not draining the beef: Excess grease makes the casserole too oily. Drain thoroughly after browning.
Baking too long: If it bakes over 25 minutes, the pasta may dry out. Watch for bubbling edges and a lightly golden top.
Serving and Pairing Suggestions
– Serve it warm straight from the oven as a main course.
– Pair with a crisp green salad or roasted broccoli to balance the richness.
– Add cornbread or garlic toast for a heartier meal.
– For a party, cut into squares and serve with a topping bar—let guests add jalapeños, sour cream, or crushed chips.
Storage and Reheating Tips
Refrigerate leftovers in an airtight container for up to 4 days.
Freeze individual portions wrapped tightly in foil or a sealed container for up to 2 months.
Reheat in the oven at 350°F for 15–20 minutes covered with foil.
Microwave individual servings with a splash of broth or water to keep it moist—cover with a damp paper towel.
FAQs
1. Can I make this casserole ahead of time?
Yes! Assemble the casserole, cover tightly, and refrigerate for up to 24 hours. Bake as directed when ready.
2. What can I use instead of beef?
Ground turkey or chicken works well. Add an extra tablespoon of olive oil for flavor.
3. Is this dish spicy?
It’s mildly spiced with chili powder, but not hot. Add jalapeños or hot sauce for more heat.
4. Can I use gluten-free pasta?
Absolutely—just follow the package instructions and avoid overcooking, as gluten-free pasta tends to be more delicate.
5. How can I make it healthier?
Use lean ground meat, low-sodium broth, and swap half the cheese for nutritional yeast or light cheese options.
Tips & Tricks
– Add a splash of Worcestershire sauce to the chili for deeper flavor.
– Use freshly shredded cheese for better melting than pre-shredded.
– Double the batch and freeze half—it’s a great make-ahead meal.
– Add a handful of spinach or shredded zucchini to sneak in extra veggies.
– Stir in a teaspoon of smoked paprika for a smoky kick.
Recipe Variations
1. Tex-Mex Style
Add ½ cup black beans and ¼ cup corn with the sauce.
Stir in ½ tsp cumin and replace cheddar with pepper jack.
Top with avocado slices and crushed tortilla chips after baking.
2. Cheesy Veggie Chili Mac
Swap ground beef for sautéed mushrooms and chopped bell peppers.
Add ½ cup diced zucchini and a pinch of oregano to the sauce.
Use a mix of mozzarella and cheddar for a creamier flavor.
3. Creamy Coney Mac Bake
Replace tomato sauce with ¾ cup marinara and ¼ cup heavy cream.
Use ground turkey and swap cheddar for Colby Jack.
Top with crushed butter crackers before baking for a crunch.
Final Thoughts
This Coney Chili Mac Casserole isn’t just a dish—it’s the kind of recipe that finds its way into family routines. It’s flexible, dependable, and full of heart. You don’t need fancy ingredients or a big budget to make it shine. Just a few pantry staples, a little patience, and a whole lot of flavor.
For me, it brings back memories of shared meals, quick laughs, and recipe cards tucked in drawers. I hope it does something similar for you—adds a little comfort to a busy week, gives your family something warm to come home to, or sparks a conversation at the table.
Sometimes, it’s these humble, baked-till-bubbly casseroles that carry the most joy. Serve it up with love—and maybe a spoonful of sour cream on top.
Coney Chili Mac Casserole
Print ThisIngredients
- 1 lb ground beef
- 2 cups cooked elbow macaroni
- 1 cup tomato sauce
- ½ cup beef broth
- 1 tbsp mustard
- 1 tbsp chili powder
- 1 cup shredded cheddar cheese, divided
- Optional Toppings: diced onions, jalapeños, sour cream or Greek yogurt, crushed tortilla chips
Instructions
Step 1: Preheat the Oven
Set your oven to 350°F (175°C). Grease a 9×13-inch baking dish.
Step 2: Brown the Beef
Cook the ground beef in a skillet over medium heat, breaking it into bits, until no pink remains (6–8 minutes). Drain off any fat.
Step 3: Simmer the Sauce
Stir in tomato sauce, beef broth, mustard, and chili powder. Let it bubble gently on low for 5–10 minutes.
Step 4: Mix in Macaroni and Cheese
Turn off the heat. Fold in the cooked macaroni and half the cheese until creamy.
Step 5: Prep for Baking
Spread the mixture in your dish. Sprinkle the remaining cheese on top.
Step 6: Bake
Bake 20–25 minutes until bubbly at the edges and the cheese is golden.
Step 7: Rest and Serve
Let the casserole sit 5 minutes. Top with onions, jalapeños, Greek yogurt, or crushed chips, if you like, and serve hot.
