The first thing I notice when this comes out of the oven is the bubbling around the edges. Under that melted Colby Jack, the elbow macaroni is tucked into a saucy chili made with ground beef, tomatoes, and kidney beans. It’s a hearty bake, but it doesn’t ask you to make a separate pot of chili and pasta sauce.
I cook the macaroni while the beef and onion brown, then bring the chili together in the same Dutch oven. Keeping those jobs moving at the same time makes the assembly straightforward, and the pasta has just one more short stint in the oven after it’s mixed with the sauce.
The result is a casserole with tender elbows, a tomato-rich chili coating, and a cheesy top that turns soft and stretchy in the oven. Give it five minutes to rest before serving, and it’s ready to scoop.
Kitchen Note
Once the beef reaches 160°F, drain off the excess fat before adding the seasonings. Leaving it in can make the tomato sauce feel oily, especially under the melted cheese.
Save this chili macaroni bake for a cozy dinner: saucy beef and beans under a bubbling Colby Jack topping.
Why the Colby Jack Belongs on Top, Not Stirred Through
It’s tempting to fold cheese into the chili macaroni, but keeping it on top gives this bake its best contrast. The chili mixture stays loose enough to coat the pasta, while the cheese melts into one even layer over the casserole. Each scoop gets that soft, stretchy topping without the cheese disappearing into the sauce.
Colby Jack works well here because it melts smoothly and has a mild flavor that doesn’t compete with the chili powder and cumin. Spreading it evenly matters more than piling it high in the middle: a level layer reaches the corners of the baking dish, so the edges don’t end up bare while the center gets all the cheese. Bake uncovered, and let the bubbling edges tell you when the casserole has heated through.
That topping also gives you a useful visual cue. The cheese should be fully melted, and you should see bubbles at the edges before you take the dish out. If the top looks melted but the sides are still quiet, give it a little more time in the oven.
What Gives the Chili Mac Its Full, Saucy Base
- Elbow macaroni — The short tubes hold the chili mixture, and their familiar shape makes the casserole easy to scoop. A standard grocery-store box works well; cook the pasta until just al dente so it holds its shape through baking.
- Ground beef — The 85% lean beef brings enough fat for a savory base without leaving an excessive amount behind. If you choose a fattier grind, expect more fat to drain away; a leaner grind gives a less rich result.
- Diced tomatoes and tomato sauce — The diced tomatoes bring pieces of tomato and their canning liquid, while tomato sauce makes the chili base cohesive. Use the diced tomatoes undrained; draining them removes liquid the pasta needs in the casserole.
- Beef broth — A little broth loosens the tomato mixture and adds a savory note. Regular beef broth is fine, and a lower-sodium version works too; the kosher salt in the chili remains the seasoning base.
- Kidney beans — Their firm, substantial texture stands up to the elbows and beef. Rinse and drain them before adding so the liquid in the can doesn’t muddy the chili.
- Chili powder, cumin, and garlic — These give the tomato base its chili character. Ground spices from an everyday pantry are a good fit; there’s no need for a specialty blend.
- Colby Jack — Its mild, creamy melt makes a generous top layer without adding a sharp bite. Pre-shredded cheese is convenient; freshly shredded cheese tends to melt a little more smoothly.
The Stovetop-to-Oven Sequence That Keeps the Pasta Tender
Get the Dish Ready and Cook the Elbows
Heat the oven to 375°F and lightly coat a 9×13-inch baking dish with nonstick cooking spray. Bring a large pot of water to a boil and cook the elbow macaroni in an 8-quart pot, following the package timing for just al dente pasta. Start checking near the shorter end of the package range so the elbows don’t get too soft. Drain them and set them aside while you make the chili.
Brown the Beef and Soften the Onion
Set a 6-quart Dutch oven over medium-high heat and add the ground beef and chopped onion. Cook for 8 to 10 minutes, breaking the beef into small pieces as it browns. The onion should be tender, and the beef should reach 160°F. Drain the excess fat before moving on to the seasonings.
Wake Up the Spices and Simmer the Chili
Stir in the minced garlic, chili powder, cumin, kosher salt, and black pepper. Cook for 30 seconds, just until the garlic and spices smell fragrant; this short cook gives them time to bloom without lingering in the hot pot. Add the undrained diced tomatoes, tomato sauce, beef broth, and rinsed kidney beans. Bring the mixture to a simmer and cook it for 5 minutes.
Top and Bake Until the Edges Bubble
Stir the drained macaroni into the chili until the elbows are evenly coated, then transfer everything to the prepared baking dish. Scatter the shredded Colby Jack evenly across the top and bake uncovered for 15 to 20 minutes. Look for melted cheese and bubbling around the edges rather than relying on the clock alone. Rest the casserole for 5 minutes before serving so it’s easier to scoop.
Three Useful Ways to Adapt This Chili Mac Bake
Make It Gluten-Free With Elbow Pasta
Replace the regular elbow macaroni with the same amount of gluten-free elbow pasta. Cook it only until just al dente, since some gluten-free pastas soften quickly once baked. The texture may be a little less springy, but the chili and cheese topping still work with it.
Trade the Kidney Beans for Black Beans
Use one 15-ounce can of drained and rinsed black beans in place of the kidney beans. Black beans have a softer bite and a slightly earthier taste, but they hold together in the tomato-and-beef mixture. Keep the rest of the method the same.
Use Monterey Jack for a Milder Cheese Cap
Swap the Colby Jack for an equal amount of shredded Monterey Jack. It melts into a soft, creamy top with a gentler flavor, so the chili seasoning comes forward more clearly. The finished bake will lose a little of Colby Jack’s buttery tang.
Storage and Reheating
- Refrigerator: Refrigerate leftovers within 2 hours and keep them covered for 3 to 4 days. The macaroni softens as it sits in the chili.
- Freezer: Freeze cooled portions in airtight containers for up to 2 to 3 months. Thaw them in the refrigerator before reheating; the pasta will be softer than when freshly baked.
- Reheating: Cover a larger portion and warm it in a 350°F oven until heated through, or microwave an individual serving in short intervals. Don’t leave it uncovered in the oven, since the macaroni can dry out before the center warms.
Questions That Come Up When Making Chili Macaroni Bake
Chili Macaroni Bake with Colby Jack Cheese Topping
Ingredients
Equipment
Method
- Heat the oven to 375°F.
- Lightly coat a 9x13-inch baking dish with nonstick cooking spray.
- Cook the macaroni in an 8-quart pot of boiling water until just al dente, following the package timing.
- Drain the macaroni.
- In a 6-quart Dutch oven over medium-high heat, cook the ground beef and onion for 8 to 10 minutes, breaking up the beef, until the onion is tender and the beef reaches 160°F.
- Drain excess fat.
- Stir in the garlic, chili powder, cumin, salt, and pepper and cook for 30 seconds, until fragrant.
- Add the diced tomatoes, tomato sauce, beef broth, and kidney beans.
- Bring to a simmer and cook for 5 minutes.
- Stir the drained macaroni into the chili until evenly combined.
- Transfer the mixture to the prepared baking dish.
- Sprinkle the Colby Jack cheese evenly over the top.
- Bake uncovered for 15 to 20 minutes, until the cheese is melted and the edges are bubbling.
- Let the bake rest for 5 minutes before serving.