If you’re craving a dinner that packs big flavor, hearty comfort, and just a bit of nostalgic joy, then you’ve got to try my crowd-pleasing Coney Chili Mac Casserole. Imagine all the best bits of a classic coney dog—savory beef, tangy mustard, punchy chili spices—married with tender macaroni and layers of gooey cheddar cheese. This casserole is the weeknight hero your family will beg for again and again. It’s simple to pull together, wildly satisfying, and just quirky enough to jazz up your regular rotation.

Coney Chili Mac Casserole Recipe - Recipe Image

Ingredients You’ll Need

The beauty of Coney Chili Mac Casserole lies in its simplicity—you probably already have most of these ingredients on hand! Each one brings something special to the dish, creating a balance of bold flavor, creamy texture, and that irresistible cheesy top.

Ground beef: The backbone of any great chili—choose lean beef for less grease but all the meaty flavor.
Cooked elbow macaroni: These cheerful little elbows are perfect for catching every bit of saucy goodness.
Tomato sauce: Adds a tangy-sweet base that ties everything together.
Beef broth: Gives the casserole extra savory depth and helps the sauce stay saucy—not dry.
Mustard: This is the secret zing that makes your Coney Chili Mac Casserole pop with flavor.
Chili powder: Brings warmth and that classic chili aroma—don’t skimp!
Shredded cheddar cheese: Divided for mixing and that glorious melty top-layer crunch.
Optional toppings: Diced onions, jalapeños, sour cream or Greek yogurt, crushed tortilla chips—perfect for customizing every serving.

How to Make Coney Chili Mac Casserole

Step 1: Preheat the Oven

Set the mood (and your oven) to 350°F (175°C). Give your trusty 9×13-inch baking dish a quick grease with butter or cooking spray. Prepping your dish ahead helps guarantee an easy cleanup and prevents any sticky, baked-on surprises later.

Step 2: Brown the Beef

Pop your skillet onto the stove and add the ground beef. Use a spatula or wooden spoon to break the meat up as it cooks, aiming for small, browned bits. After 6–8 minutes, no pink should remain. Drain off any excess fat to keep the casserole from getting greasy. This step builds the deeply savory foundation for your Coney Chili Mac Casserole.

Step 3: Simmer the Sauce

Bring in the tomato sauce, beef broth, zippy mustard, and that essential chili powder. Stir everything together right in the skillet. Let it bubble away gently on low heat for 5–10 minutes, stirring now and then. This short simmer thickens the sauce and lets the spices bloom for extra richness.

Step 4: Mix in Macaroni and Cheese

Kill the heat and gently fold in the cooked macaroni and half of your shredded cheddar. The cheeses will melt into the beefy, chili-flecked sauce, creating an ultra-creamy, flavorful base that’s impossible to resist. Don’t overmix—you want those elbows coated but not mushy.

Step 5: Prep for Baking

Scoop the hearty mixture into your prepared dish. Sprinkle the remaining cheddar over the top to ensure every serving gets that irresistible cheesy crust. This not only looks gorgeous but also adds a layer of texture you’ll crave.

Step 6: Bake

Bake in the center of the oven for 20–25 minutes. You’re looking for brown, bubbly edges and golden cheese on top. That sizzle and aroma filling your kitchen? It’s exactly what makes Coney Chili Mac Casserole so beloved.

Step 7: Rest and Serve

Resist the urge to dig in straight away! Let your Coney Chili Mac Casserole rest for at least five minutes, which helps it set for easier slicing. Then add your favorite toppings—crunchy onions, zingy jalapeños, a dollop of Greek yogurt, or even a sprinkle of crushed chips—before devouring every bite hot.

How to Serve Coney Chili Mac Casserole

Garnishes

This dish truly shines with a little flair on top! Classic sweet diced onions, sliced jalapeños for a kick, dollops of cool sour cream or Greek yogurt, and a sprinkle of crunchy crushed tortilla chips all add color, flavor, and fun texture to your Coney Chili Mac Casserole. Don’t be shy—let everyone customize their own plate.

Side Dishes

While it easily stands alone as a full meal, Coney Chili Mac Casserole pairs brilliantly with a crisp green salad tossed in a tangy vinaigrette, roasted vegetables, or even classic cornbread. If you’re feeling playful, offer a mix of pickles or coleslaw on the side for a vintage diner vibe.

Creative Ways to Present

For casual gatherings, serve directly from the baking dish, family-style. For parties, scoop Coney Chili Mac Casserole into individual ramekins or even hollowed-out bell peppers for a fun twist! Leftovers also make a fabulous stuffed baked potato or tortilla filling the next day—get creative and watch your guests light up.

Make Ahead and Storage

Storing Leftovers

Any leftovers can be covered tightly and stored in the refrigerator for up to four days. The flavors actually deepen overnight, so don’t be surprised if tomorrow’s Coney Chili Mac Casserole is even tastier than you remember!

Freezing

This casserole is freezer-friendly! Let the baked dish cool completely, then wrap portions or the whole pan in plastic and foil. Freeze for up to two months. For best results, thaw overnight in the refrigerator before reheating.

Reheating

To reheat, simply cover and warm in a 350°F oven until hot and bubbly, usually about 20 minutes. Individual servings microwave well, too—just add a splash of broth or water to keep it moist. Don’t forget your favorite toppings to bring that fresh-baked feel back to each serving.

FAQs

Can I use a different pasta shape in my Coney Chili Mac Casserole?

Absolutely! While elbow macaroni is classic, feel free to substitute shells, rotini, or penne. Just be sure to use a shape that can hold up to the hearty sauce and doesn’t get mushy after baking.

Can I make Coney Chili Mac Casserole vegetarian?

You sure can! Swap out the ground beef for your favorite plant-based crumbles or cooked lentils, and use vegetable broth in place of beef broth. You’ll still get all those comforting flavors with a meatless twist.

How spicy is this casserole?

As written, this Coney Chili Mac Casserole is mild with just a bit of warmth from the chili powder. If you want more heat, amp it up by adding cayenne, diced jalapeños, or a few splashes of hot sauce to the mix!

Is it possible to assemble this casserole in advance?

Yes! You can prepare the casserole through Step 5 and refrigerate it (covered) for up to 24 hours before baking. When ready to bake, add a few extra minutes to the oven time until it’s fully heated through.

What kind of cheese works best on top?

Sharp cheddar is the gold standard for its bold flavor and melting quality. However, you can mix in Monterey Jack or Pepper Jack for a creamy, meltier finish or sprinkle a handful of Parmesan for a tangy kick.

Final Thoughts

If you’re looking to shake up dinnertime with something fun, family-friendly, and utterly delicious, give this Coney Chili Mac Casserole a try. It’s simple, versatile, and sure to become a regular comfort food staple at your table. Enjoy every gooey, cheesy bite!