Happy National Mac and Cheese Day! Today, we are taking ultimate comfort food and giving it a massive backyard upgrade. Forget the boxed stuff—we’re blending rich, sharp cheddar with the deep, smooth flavor of smoked gouda, tossing in savory grilled kielbasa, and letting it absorb that perfect wood-fired smoke flavor out on the Pit Boss pellet grill.
If you are looking for a creamy, crowd-pleasing meal that elevates your weekend cookout, this Smoked Kielbasa Mac & Cheese is the exact recipe you need.
The Secret to Next-Level Mac
The secret to this recipe comes down to a perfect blend of cheeses and a solid cream base. Instead of relying on a single cheese, we use a mix of sharp cheddar for that classic bite and a whole wheel of smoked gouda to double down on the rich, smoky profile. To ensure it stays incredibly smooth and doesn’t dry out in the smoker, we build a velvety cheese sauce using a traditional roux, half-and-half, and a generous block of cream cheese.
Let’s head outside and get cooking!
Full Recipe: Creamy Smoked Kielbasa Mac & Cheese
- Prep Time: 20 minutes
- Cook Time: 1 hour – 2 hours (depending on how much smoke you desire)
- Pellet Grill Temperature: 225 degrees
- Grill Fuel: Pecan or Hickory Pellets
Ingredients
The Pasta & Protein
- 1 lb elbow macaroni noodles
- 14 oz Polska Kielbasa loop
- 1–2 tbsp Creole seasoning (to taste)
The Ultimate Cheese Blend
- 3 cups sharp cheddar cheese, freshly grated
- 1 1/2 to 2 cups smoked gouda cheese, freshly grated
The Creamy Sauce Base
- 1/4 cup unsalted butter
- 4 tbsp all-purpose flour
- 2 cups half-and-half
- 1 tbsp ground mustard
- 8 oz cream cheese
Step-by-Step Instructions
1. Prep the Pasta and Cheese
Boil the elbow macaroni noodles according to the package instructions until they are just al dente. Drain and set aside. While the pasta cooks, freshly grate your sharp cheddar and smoked gouda into a bowl, mixing them together.
2. Fire Up the Pit Boss
Preheat your Pit Boss pellet grill (or your smoker of choice) to 225 degrees.
3. Grill the Kielbasa
Place the kielbasa loop directly onto the preheated grill grates. Let it slice up and cook for a few minutes to develop a light exterior char and absorb some initial smoke. Remove, slice it into bite-sized rounds, and set aside.
4. Build the Cheese Sauce
Set a cast-iron Dutch oven over your outdoor burner or stove. Melt the 1/4 cup of butter, then whisk in the 4 tablespoons of flour to create a roux. Cook the roux for 1–2 minutes until it is lightly golden and bubbly.
Slowly pour in the half-and-half, whisking constantly as it simmers and thickens. Stir in the ground mustard, then drop in the full 8-ounce block of cream cheese, stirring until completely melted and smooth. Turn the heat down to low, add your shredded cheddar and gouda blend, and stir until you have a thick, velvety cheese sauce.
5. Combine and Smoke
Remove the Dutch oven from the direct burner heat. Dump the cooked macaroni noodles straight into the cheese sauce, tossing until every noodle is heavily coated. Generously dust the top of the mac with your favorite Creole seasoning.
Move the open Dutch oven onto your pellet grill grates next to your sliced kielbasa. Let everything smoke at 225 degrees for about 15 minutes to let that wood-fired flavor infuse into the cheese.
6. The Final Mix
Nestle the smoked kielbasa slices right into the top of the creamy mac and cheese. Next, smoke it on the grate for as little or as long as you desire. I recommend about 1 hour, but for less smoke remove sooner and for more – go 2 hours! This part is up to you. Once removed, top with an extra pinch of Creole seasoning if you like a little extra kick, hit it with a final few minutes of heat, and serve it hot straight out of the cast iron!
What’s your ultimate mix-in? Do you stick to classic kielbasa, or do you like to throw in jalapeños, bacon, or a splash of hot sauce? Let me know your favorite way to customize mac and cheese in the comments below! Don’t forget to subscribe to the blog for more backyard BBQ recipes and grilling tips.