Description

This Decadent BBQ Pulled Pork Mac and Cheese combines tender, smoky pulled pork with creamy, cheesy macaroni for the ultimate comfort food dinner. Featuring a rich cheese sauce made from smoked gouda, sharp cheddar, and mozzarella, plus tangy barbecue pulled pork layered and baked to perfection, this hearty meal is perfect for busy weeknights or satisfying leftovers.

Ingredients

Scale

For the Pulled Pork:

2 cups pulled pork (shredded)
1 cup barbecue sauce (Sweet Baby Ray’s recommended)

For the Pasta:

16 oz short-cut pasta (elbow macaroni or cavatappi preferred)
1 tsp kosher salt (for pasta water)

For the Cheese Sauce:

1 tsp kosher salt
1/2 tsp black pepper
1/2 tsp red pepper flakes (optional but recommended)
2 tsp granulated garlic
3 cups whole milk (warmed slightly)
8 oz smoked gouda cheese, freshly shredded
8 oz sharp cheddar cheese, freshly shredded
8 oz mozzarella cheese, freshly shredded
4 tbsp butter (room temperature)
1 tsp onion powder
1/2 tsp mustard powder (or 1 tbsp prepared yellow mustard as substitute)
4 tbsp all-purpose flour (King Arthur preferred)

Instructions

Prepare Mise en Place and Cook Pasta: Shred the gouda, cheddar, and mozzarella cheeses, reserving one-third for topping. Warm the milk slightly to avoid roux clumping. Bring a large pot of salted water to a rolling boil, then cook the pasta until al dente according to package directions. Drain and set aside.
Build the Cheese Sauce Base: In a large heavy-bottomed pot over medium heat, melt the butter. Add granulated garlic, onion powder, mustard powder, black pepper, and red pepper flakes; cook for 30 seconds until fragrant. Whisk in flour to make a roux and cook for 1 minute. Slowly pour in the warmed milk while whisking constantly to avoid lumps. Continue cooking, stirring occasionally, until sauce thickens, about 4–5 minutes.
Finish the Cheese Sauce and Combine with Pasta: Remove sauce from heat to prevent scorching. Stir in two-thirds of the shredded cheeses until melted and smooth. Taste and adjust seasoning with salt and pepper as needed. Fold in the cooked pasta until fully coated in the cheese sauce.
Prepare Pulled Pork and Assemble: Combine pulled pork with barbecue sauce in a bowl and mix well. Preheat oven to 400°F (200°C). In a 9×13 inch baking dish, spread half of the cheesy pasta mixture. Layer half of the pulled pork mixture over the pasta, gently mixing it in. Add the remaining pasta, then top evenly with remaining pulled pork and reserved cheese. Press down lightly to help cheese melt evenly.
Bake, Broil, and Serve: Bake for 15 minutes to melt and meld the cheeses. Broil for 2 minutes until the top is golden and bubbly—watch carefully to prevent burning. Let the dish rest for 5 minutes before serving to allow the cheese sauce to set for easier portions.

Notes

Do not add cheese to boiling milk to prevent grainy sauce; remove from heat first.
Aim to undercook pasta by 2 minutes as it continues cooking in the oven and absorbs cheese sauce.
Grate your own cheese from blocks rather than using pre-shredded for smoother melting.
Warm pulled pork with barbecue sauce on stovetop to retain moisture and blend flavors rather than microwaving.
Store leftovers in an airtight container in the fridge for up to 4 days; flavors improve after resting.
Freeze in portions for up to 3 months; thawed texture may slightly change but still delicious.
Reheat with a splash of milk in microwave or cover with foil and warm in oven at 350°F.

Prep Time: 15 minutes
Cook Time: 30 minutes
Category: Main Course
Method: Baking
Cuisine: American

Keywords: BBQ pulled pork, mac and cheese, comfort food, cheesy pasta, baked pasta, smoked gouda, cheddar, mozzarella, dinner, leftovers, barbecue sauce