Creamy Smoked Ham Mac and Cheese

Smoked Ham Mac and Cheese made on a Pit Boss smoker is outstanding — a grown-up take on a classic comfort dish. This recipe uses homemade cheese sauce instead of a box mix, resulting in a rich, creamy pasta that pairs perfectly with smoky ham. It’s a crowd-pleaser for anyone who loves creamy, cheesy pasta and makes excellent leftovers.

Smoked dishes aren’t just for summer — they work any time of year. It can be tricky to find sides that match low-and-slow smoked mains, and this smoked mac and cheese is an ideal complement. It holds up well as next-day leftovers and can even improve after resting in the fridge.

I prepared this version on a Pit Boss Pro 1100 pellet grill, cooking low and slow to build subtle smoke flavor. Any smoker will work; the important part is knowing how your unit delivers smoke so you can adjust timing for your preferred intensity.

Smoked Ham Mac and Cheese Ingredients

Macaroni noodles — Elbow macaroni is classic, but rotini or shells work nicely if you prefer more sauce cling.

Butter — Salted or unsalted, according to taste.

Diced ham — Leftover smoked ham is ideal, but store-bought diced ham or ham steaks work fine.

Flour — For thickening the bechamel-style sauce.

2% milk — You can substitute heavy cream for an even richer sauce, but 2% gives great creaminess without being overly heavy.

Cream cheese — Cut into small cubes or bring to room temperature so it melts smoothly into the sauce.

Salt and black pepper — To taste.

Parmesan, extra-sharp cheddar, gouda, and white cheddar — A blend of cheeses creates depth: use half of the shredded mix while building the sauce and reserve the rest for topping the casserole before smoking.

How to Make Smoked Homemade Ham Macaroni & Cheese

1. Cook the pasta: Prepare the pasta according to package directions, cooking it slightly al dente in a large pot of boiling water. Drain and set aside.

2. Make the roux: In a medium or large saucepan, melt the butter over medium-low heat. Whisk in the flour and cook until the mixture is thick and bubbly, forming a smooth roux.

3. Add milk: Gradually whisk in the milk and bring to a gentle boil over medium-high heat. Let the sauce simmer for about five minutes until it thickens.

4. Add cream cheese and season: Carefully stir in the cubed cream cheese and season with salt and black pepper. Stir until the cream cheese is fully melted and incorporated into the sauce.

5. Add cheese: In a large bowl, combine half of the shredded cheeses, then slowly mix them into the warm cream sauce until smooth.

6. Combine with pasta: Fold the cooked pasta into the cheese sauce, making sure it’s evenly coated.

7. Prep the ham: Dice the ham. In a separate skillet over medium heat, warm the ham with a small amount of minced garlic until it takes on a little color and aroma. Browning the ham helps develop flavor and renders any excess fat.

8. Mix ham into pasta: Stir the browned ham into the cheesy pasta mixture.

9. Prepare the pan: Spray a 9×13-inch disposable aluminum pan or an oven-safe casserole dish with nonstick spray. Spread the cheesy pasta evenly in the pan.

10. Top with remaining cheese: Combine the remaining shredded cheese and sprinkle it across the top of the pasta for a melty, golden finish.

11. Smoke for flavor: Set your smoker to the smoke setting and smoke the mac and cheese for about 20 minutes to absorb smoke flavor. Increase the setting to hold at about 225°F and smoke for another hour, or until the casserole is bubbly and the cheese on top has melted.

12. Finish and serve: If excess grease appears from the ham, blot the surface with a paper towel. Stir briefly if desired, then serve hot and enjoy.

Serve immediately while warm. This dish is hearty enough to stand beside many grilled or smoked mains and also works as a centerpiece on its own for a comfort-food meal.

Ways to Change Up Smoked Mac and Cheese

• Add crispy bacon for extra smokiness and crunch.
• Use Colby Jack or Monterey Jack for a milder, creamier melt.
• Stir in smoked pulled pork for a BBQ-style casserole.
• Add sliced jalapeños or hot sauce for heat.
• Mix in roasted bell peppers, garlic, or fresh herbs for brightness.
• Top with panko breadcrumbs or Cajun seasoning for texture and spice.

What to Serve With Homemade Mac and Cheese

Grilled mains: Bratwurst, burgers, grilled chicken thighs, or salmon pair beautifully with this rich side.

Smoked mains: Smoked chicken, pulled pork, smoked ham, brisket, or smoked pork chops all complement the smoky cheese flavors.

Smoked sides: Try smoked baked potatoes, smoked green bean casserole, smoked sweet potato casserole, or smoked deviled eggs to create a full smoked-meal spread.

Storage and Reheating

Refrigerate leftovers in an airtight container for up to five days. To freeze, cool completely and store in airtight containers or freezer bags for up to 90 days; freezing while still hot can make the texture mushy.

Reheat in the microwave, stirring often and adding a splash of milk if it dries out. Covering with a damp paper towel helps retain moisture. For best results, reheat in a 350°F oven for about 15 minutes until warmed through and bubbly.

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