Overnight Smoked Mac and Cheese for a Crowd

🧂 Ingredients

1. Pasta
   1. 2 lbs pasta (elbows, cavatappi, or shells)
   2. Salted water
2. Cheese Sauce
   1. 1 cup (2 sticks) butter
   2. 1 cup all-purpose flour
   3. 8 cups whole milk
   4. 2 cups heavy cream (1 cup for sauce + 1 cup reserved for overnight moisture)
   5. 6 cups (24 oz) shredded sharp cheddar
   6. 4 cups (16 oz) shredded gouda or smoked gouda
   7. 2 cups (8 oz) shredded Monterey Jack or mozzarella
   8. 1 Tbsp mustard powder
   9. 1 Tbsp smoked paprika
   10. 2 tsp garlic powder
   11. 2 tsp onion powder
   12. Salt & pepper to taste
3. Topping (added the next day)
   1. 3 cups panko
   2. ¾ cup (1½ sticks) melted butter
   3. 1 cup grated parmesan

🥣 Instructions — Day Before Smoking

1. Cook the pasta
   1. Boil pasta in salted water until just under al dente (about 1 minute less than the box says).
   2. Drain and set aside.
2. Make the roux
   1. Melt 1 cup butter in a large pot.
   2. Whisk in 1 cup flour.
   3. Cook 2-3 minutes until blond and smooth.
3. Add milk, cream, and seasonings
   1. Whisk in slowly:
      1. 8 cups milk
      2. 1 cup heavy cream
   2. Add:
      1. Mustard powder
      2. Smoked paprika
      3. Garlic powder
      4. Onion powder
      5. Salt + pepper
      6. Simmer 5-7 minutes until thickened.
4. Add the cheese
   1. Off the heat, stir in:
      1. Cheddar
      2. Gouda
      3. Monterey Jack
   2. Stir until smooth and melty.
5. Add overnight moisture insurance
   1. Stir in the extra 1 cup heavy cream (this makes up for what gets absorbed overnight).
6. Combine with pasta
   1. Mix the cooked pasta into the cheese sauce until evenly coated.
7. Assemble the pan
   1. Pour everything into your large foil pan.
   2. Smooth the top.
8. Cool before covering
   1. Let it sit 20-30 minutes so condensation doesn't make the top watery.
9. Cover & refrigerate
   1. Wrap tightly with foil or plastic wrap.
   2. Refrigerate overnight (up to 24 hours).

💨 Instructions — Day of Smoking

1. Remove from fridge early
   1. Take the pan out 30-45 minutes before smoking so it warms slightly.
2. Add the topping, mix together:
   1. Panko
   2. Melted butter
   3. Parmesan
3. Spread evenly over the top.
4. Optional: Light dusting of BBQ rub.
5. Smoke it
   1. Temperature: 225-250°F
   2. Wood: Hickory, pecan, apple, or cherry
   3. Time: 60-90 minutes
   4. You're mostly adding smoke and crisping the topping, not "cooking" it.
6. Check texture
   1. If the top looks dry or the edges got thick:
      1. Drizzle 2-4 Tbsp milk around the edges
      2. Gently stir the edges back into the center
7. Optional finish
   1. Broil 2-3 minutes for a crisp, golden crust.

🍽️ Ready to Serve

It'll be creamy, smoky, and still soft even after an overnight rest. The extra cream ensures it reheats beautifully.