Ingredients
Scale
Pasta & Protein Base
- 16 oz elbow macaroni (or substitute with cavatappi, rotini, or shells)
- 3 cups cooked chicken, shredded (grilled, roasted, or rotisserie)
- 1 cup BBQ sauce (choose your favorite style—sweet, smoky, spicy, or tangy)
- 1 tablespoon honey (optional, to balance tanginess)
Cheese Sauce
- 2 tablespoons unsalted butter
- 2 tablespoons all-purpose flour
- 2 cups whole milk (warm)
- 1 cup heavy cream (optional for added richness)
- 1 teaspoon garlic powder
- 1 teaspoon onion powder
- ½ teaspoon smoked paprika
- Salt and freshly ground black pepper, to taste
- 2 cups sharp cheddar cheese, freshly grated
- 1 cup mozzarella cheese, grated (or substitute with smoked gouda or fontina)
Crunchy Topping (Optional but Recommended)
- ½ cup panko breadcrumbs
- 2 tablespoons melted butter
- ¼ cup grated Parmesan cheese (optional for umami boost)
Instructions
1. Cook the Pasta
- Bring a large pot of salted water to a boil.
- Add the macaroni and cook until just al dente (about 1–2 minutes less than package instructions).
- Drain the pasta and toss lightly with oil to prevent sticking. Set aside.
2. Prepare the Chicken
- If using cooked chicken, shred it with two forks or chop into bite-sized pieces.
- Toss the shredded chicken with:
- 1 cup of BBQ sauce
- 1 tablespoon of honey (optional, to round out smoky flavor)
- Set aside to allow the flavors to marinate while you make the sauce.
3. Make the Cheese Sauce
- In a large saucepan, melt 2 tablespoons of butter over medium heat.
- Whisk in 2 tablespoons of flour, stirring constantly for 1–2 minutes until the roux is lightly golden.
- Gradually add the warm milk and cream, whisking to ensure a smooth consistency.
- Stir in:
- Garlic powder
- Onion powder
- Smoked paprika
- Salt and pepper to taste
- Reduce heat to low once thickened slightly, and stir in:
- Cheddar cheese
- Mozzarella cheese
- Stir until fully melted and velvety smooth.
4. Assemble the Casserole
- Preheat your oven to 375°F (190°C).
- In a large bowl, combine the cooked pasta, cheese sauce, and BBQ chicken.
- Mix until everything is evenly coated.
- Transfer the mixture into a greased 9×13-inch baking dish.
5. Add the Crunchy Topping
(Optional, but adds a lovely golden crust)
- In a small bowl, mix:
- ½ cup panko breadcrumbs
- 2 tablespoons melted butter
- Grated Parmesan (optional)
- Sprinkle evenly over the top of the pasta mixture.
6. Bake the Dish
- Place the casserole in the oven and bake for 20–25 minutes, or until the top is golden and bubbling around the edges.
- Remove from the oven and let it rest for 5 minutes before serving.
Notes
- Cheese quality matters
Always grate cheese fresh from the block. Pre-shredded cheese contains anti-caking agents that prevent smooth melting. - Watch the pasta cook time
Undercook the pasta slightly since it will continue cooking in the oven. - Don’t skip the roux
The butter-flour base ensures a stable and creamy cheese sauce that doesn’t separate. - Customize BBQ flavors
Not all BBQ sauces taste the same—try hickory, chipotle, or honey mustard varieties to suit your preference. - Make ahead option
Assemble the dish ahead and refrigerate, unbaked, for up to 24 hours. Add 5–10 minutes to the baking time when cooking from cold. - Freezing instructions
You can freeze the fully assembled (unbaked) casserole. Wrap tightly in foil and store for up to 2 months. Thaw in the fridge overnight before baking.
- Prep Time: 20 minutes
- Cook Time: 25 minutes