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Coney Chili Mac Casserole

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Coney Chili Mac Casserole is a hearty, cheesy, and nostalgic dish that combines the best of chili dogs, mac and cheese, and baked casseroles into one crowd-pleasing meal. Perfect for weeknight dinners, potlucks, tailgates, or cozy Sunday suppers, this casserole features tender elbow macaroni smothered in a rich chili-spiced tomato beef sauce, topped with melted cheddar and optional crunchy toppings.

Ingredients

  • 1 lb ground beef (chuck or lean)
  • 2 cups cooked elbow macaroni (or shells, rotini)
  • 1 cup tomato sauce
  • 1/2 cup beef broth
  • 1 tablespoon yellow mustard
  • 1 tablespoon chili powder
  • 1/2 cup shredded cheddar cheese
  • Optional toppings: crushed butter crackers or crispy fried onions
  • Optional add-ins: diced onion, minced garlic, hot sauce

Preparation Steps

Preheat and Prepare Casserole Dish

Preheat the oven to 375°F (190°C). Grease a medium casserole dish or an 8×8-inch baking dish with nonstick spray or a light coating of butter. This prevents sticking and helps the casserole bake evenly.

Cook the Ground Beef

In a large skillet over medium heat, cook the ground beef until browned and crumbled, about 6–8 minutes. Drain any excess grease if necessary.

Add Sauce and Seasonings

Stir in the tomato sauce, beef broth, mustard, and chili powder. Allow the mixture to simmer for 5–7 minutes, letting the flavors meld and the sauce thicken slightly. For extra flavor, you can add diced onions, minced garlic, or a few dashes of hot sauce.

Combine with Macaroni

Add the cooked elbow macaroni to the chili mixture and stir until the pasta is evenly coated. This ensures every bite has a perfect balance of pasta and flavorful sauce.

Assemble the Casserole

Pour the chili-macaroni mixture into the prepared baking dish. Sprinkle shredded cheddar cheese evenly on top. Add optional crushed crackers or crispy fried onions for a golden, crunchy topping.

Bake

Bake uncovered for 20–25 minutes, or until the casserole is hot, bubbly, and the cheese has melted with golden edges.

Serving Suggestions

This casserole is filling on its own, but pairing it with sides can make a complete meal:

  • Crisp green salad with ranch or vinaigrette
  • Steamed green beans or roasted broccoli
  • Cornbread muffins or garlic toast
  • Diner-style: serve with pickle slices, diced raw onions, or a drizzle of yellow mustard for an authentic Coney dog feel
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Leftovers and Storage

  • Refrigerate: Store in an airtight container for up to 4 days.
  • Reheat: Warm in the oven at 350°F or microwave individual portions.
  • Freeze: Assemble before baking (without toppings) and freeze for up to 2 months. Add cheese and toppings before baking from frozen or thawed.

Variations and Substitutions

  • Spicy version: Add jalapeños, cayenne pepper, or hot sauce to the meat mixture.
  • Cheese variations: Use Monterey Jack, pepper jack, or a blend of sharp cheddar.
  • Tex-Mex twist: Stir in black beans and corn; top with crushed tortilla chips.
  • Protein swap: Substitute ground turkey or plant-based crumbles for a lighter version.
  • Creamier version: Mix a cheese sauce into the pasta before baking for extra richness.

Tips for the Best Coney Chili Mac Casserole

  • Don’t skip the mustard and chili powder—they provide that signature “Coney dog” flavor.
  • Ensure the macaroni is cooked al dente to avoid mushy pasta after baking.
  • Lightly grease the baking dish for easy cleanup and even browning.
  • Layer the cheese evenly for consistent melting.

Frequently Asked Questions

Can I make this casserole ahead of time?
Yes, assemble the casserole and freeze before baking. Add cheese and toppings just before cooking.

Is it possible to make it vegetarian?
Use plant-based ground meat or lentils instead of beef, and vegetable broth instead of beef broth.

Can I use different pasta?
Yes, short pasta like shells, rotini, or penne works well.

How spicy is this casserole?
The base recipe is mild, but adding chili powder, hot sauce, or jalapeños can easily increase the heat.

Does it reheat well?
Yes, leftovers taste even better the next day. Reheat in the oven or microwave until warm and bubbly.

What can I use for toppings?
Crushed butter crackers, crispy fried onions, or even breadcrumbs can add a delightful crunch.

Coney Chili Mac Casserole is a true comfort food favorite, combining bold flavors, cheesy goodness, and a touch of nostalgic fun. Its versatility, ease of preparation, and satisfying taste make it a go-to recipe for busy weeknights, family dinners, or casual gatherings. Whether enjoyed fresh from the oven or reheated the next day, this casserole promises smiles at every bite.