Coney Chili Mac Casserole

Nothing brings comfort like a cheesy, beefy, and slightly spicy casserole straight from the oven—and this Coney Chili Mac Casserole delivers all that and more.

Inspired by the iconic coney chili dogs, this dish swaps the bun for elbow macaroni and transforms all that savory goodness into a cozy, one-pan meal that hits every comfort food note. It's the perfect weeknight dinner when you're craving something hearty, nostalgic, and incredibly satisfying.

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The first time I made this casserole, I was amazed by how quickly it disappeared. The combination of seasoned ground beef, tender pasta, and a flavorful tomato-chili sauce topped with melty cheddar cheese is simply irresistible.

It’s easy enough to whip up on a busy weeknight but tasty enough to serve when company comes over. Add a crispy topping like crushed crackers or fried onions, and you’ve got a dinner that’s hearty, homey, and guaranteed to please even picky eaters.

Why You’ll Love Coney Chili Mac Casserole

• Quick and easy: Comes together in under an hour with minimal prep.
• Budget-friendly: Uses affordable, pantry-friendly ingredients.
• Crowd-pleaser: A hit with kids, teens, and adults alike.
• One-dish meal: All your carbs, protein, and flavor in one comforting casserole.
• Make-ahead: Great for prepping the night before or freezing for later.
• Freezer-friendly: Perfect for batch cooking and meal planning.
• Customizable: Add veggies, swap proteins, or spice it up to suit your taste.

Ingredients You’ll Need

For the Casserole:

• 1 lb ground beef
• 2 cups cooked elbow macaroni (about 1 cup dry pasta)
• 1 cup tomato sauce
• ½ cup beef broth (or water with a bouillon cube)
• 1 tablespoon mustard (yellow or Dijon both work well)
• 1 tablespoon chili powder
• ½ cup shredded cheddar cheese (plus more for topping if desired)

Optional Topping:

• Crushed crackers or crispy onions (for added crunch and flavor)

Step-by-Step Instructions

1. Preheat Oven:
   • Preheat your oven to 375°F (190°C). Grease an 8x8 or 9x9-inch baking dish.
2. Cook the Beef:
   • In a large skillet over medium heat, cook the ground beef until fully browned. Use a wooden spoon to break it into crumbles. Drain excess fat if necessary to prevent greasiness.
3. Make the Sauce:
   • Stir in the tomato sauce, beef broth, mustard, and chili powder. Let the mixture simmer for about 5–8 minutes. The flavors will start to meld, and the sauce will thicken slightly.
4. Combine with Pasta:
   • Stir the cooked macaroni into the skillet with the beef and sauce mixture. Mix until everything is evenly coated. If the mixture looks too thick, add a splash of broth or water.
5. Assemble the Casserole:
   • Spoon the beef and macaroni mixture into the prepared baking dish. Use a spatula to level the surface.
   • Sprinkle cheddar cheese evenly over the top.
   • Add optional crushed crackers or crispy onions for an extra layer of crunch.
6. Bake:
   • Bake uncovered for 20–25 minutes, or until the cheese is fully melted and the casserole is bubbly around the edges.
7. Serve:
   • Let the casserole rest for about 5 minutes before serving to help it set. Garnish with chopped fresh parsley or an extra sprinkle of shredded cheese, if desired.

Serving and Storage Tips

• Serve with sides: This casserole pairs beautifully with a crisp green salad, steamed green beans, or buttered corn.
• Leftovers: Store in an airtight container in the refrigerator for up to 4 days. Reheat in the microwave or oven.
• Freezing: Allow to cool completely, then wrap tightly in foil or transfer to a freezer-safe container. Freeze for up to 2 months.
• Reheating: Thaw overnight in the fridge and reheat at 350°F for 20 minutes, or microwave single servings for 1–2 minutes.

Helpful Notes

• Cheese swap: Monterey Jack, mozzarella, or a Mexican blend cheese all melt beautifully and add variety.
• Meat alternatives: Ground turkey, chicken, or vegetarian crumbles work great if you prefer a lighter or meatless version.
• Boost flavor: Sauté diced onions, garlic, or bell peppers with the ground beef.
• Extra chili flair: Add a dash of Worcestershire sauce, smoked paprika, or your favorite hot sauce.
• Make it saucier: Add an extra ¼ cup of broth or a spoonful of tomato paste for a richer sauce.

Frequently Asked Questions

1. Can I make this ahead of time?
   Yes! Assemble the casserole up to 24 hours in advance and refrigerate. Add 5 extra minutes to the baking time if coming straight from the fridge.
2. Can I use different pasta?
   Absolutely. Rotini, penne, or small shells work well and hold the sauce nicely.
3. Can I double the recipe?
   Definitely! Use a 9x13-inch dish and increase bake time to 30–35 minutes.
4. What if I don’t have beef broth?
   Use vegetable broth, chicken broth, or just water with a bit of extra seasoning.
5. Is this spicy?
   It has a mild chili flavor. For more kick, add cayenne pepper or diced jalapeños.
6. Can I make this gluten-free?
   Yes! Use gluten-free pasta and check labels on broth and toppings for gluten content.

Final Thoughts

Coney Chili Mac Casserole is the perfect way to enjoy bold chili flavor in a comforting, cheesy pasta bake. It’s a nostalgic twist on two favorites: chili mac and coney dogs, rolled into one irresistible dish. Simple to prepare, endlessly customizable, and totally satisfying, this casserole will quickly become a go-to meal for busy weeknights or casual get-togethers. Serve it hot, topped with a little extra cheese or crunch, and enjoy every hearty bite!

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