Coney Chili Mac Casserole (The Ultimate Comfort Food Mashup!)

There’s something magical about combining two iconic comfort foods into one glorious dish. The first time I made this Coney Chili Mac Casserole, I watched my family devour every cheesy, chili-laden bite—it’s everything we love about Coney Island chili dogs and mac and cheese merged into one bubbling, golden casserole. The savory ground beef chili with its signature tangy mustard flavor mingles perfectly with tender macaroni and sharp melted cheddar, creating pure comfort in every forkful.

Growing up in the Midwest, Coney dogs were a staple at diners and family gatherings—that unique combination of spiced beef chili, yellow mustard, and melted cheese over a hot dog was always irresistible. This casserole captures all those nostalgic flavors but transforms them into a hearty, family-friendly bake that’s perfect for feeding a crowd or enjoying as leftovers throughout the week.

You’ll get a rich, flavorful chili base loaded with perfectly seasoned ground beef, tangy tomato sauce with a hint of mustard, and tender elbow macaroni all blanketed with melted cheddar cheese that gets gorgeously golden on top. Whether it’s a busy weeknight, game day, or potluck dinner, this casserole delivers bold, satisfying flavor in just 40 minutes.

Prep Time: 15 min | Cook Time: 25 min | Total: 40 min
Yield: 6-8 servings | Difficulty: Easy

Quick Stats Box:

Cuisine: American / Midwest Comfort Food
Course: Main Dish / Dinner / Casserole
Diet: Can be modified for gluten-free
Best for: Weeknight dinners, potlucks, game day meals, family gatherings

Why This Recipe Works

Two classics in one — All the flavors of a Coney Island chili dog meet creamy mac and cheese in one dish
Signature tangy flavor — Mustard and chili seasoning create that authentic Coney dog taste everyone craves
Easy one-dish dinner — Everything bakes together in a single casserole for simple prep and cleanup
Crowd-pleaser guaranteed — Bold, cheesy, and packed with meat—hits every comfort food craving
Perfect for meal prep — Reheats beautifully and tastes even better the next day

Ingredient Spotlight

Ground Beef: The Hearty Foundation

Ground beef forms the base of the Coney-style chili that makes this casserole special. Use 80/20 ground beef for the best balance of flavor and moisture—leaner beef can be dry. Some versions even use sliced hot dogs or a combination of both for authentic chili dog flavor. Breaking the meat into small pieces ensures every bite has some in it.

Mustard: The Signature Tang

Yellow mustard is the secret ingredient that gives this casserole its authentic Coney dog flavor. Just one tablespoon added to the chili mixture creates that tangy, slightly sharp taste that sets Coney-style chili apart from regular chili. Don’t skip this—it’s what makes the dish taste like your favorite chili dog.

Chili Seasoning: The Flavor Builder

A blend of chili powder, cumin, paprika, and other warm spices creates the bold, savory backbone of the dish. You can use a pre-made chili seasoning packet for convenience or mix your own with cumin, paprika, oregano, and cayenne for customized heat. Smoked paprika or chipotle powder adds an extra layer of depth.

Ingredients

For the Casserole Base:

1 lb ground beef (80/20 blend)
8 oz (2 cups) elbow macaroni, cooked al dente
1 small onion, finely diced
2-3 garlic cloves, minced
2 tablespoons tomato paste
1 cup tomato sauce
½ cup beef broth
1 tablespoon yellow mustard
1 tablespoon chili powder
2 teaspoons ground cumin
½ teaspoon smoked paprika (optional, for depth)
Salt and black pepper to taste

For the Cheese Topping:

1½-2 cups shredded sharp cheddar cheese
Optional: ½ cup pepper jack for extra heat

Optional Add-ins and Toppings:

1 (15 oz) can pinto or kidney beans, drained
Sliced jalapeños
Chopped green onions or scallions
Yellow mustard drizzle for serving
Sour cream
Crushed tortilla chips for crunch

Ingredient Notes:

Quality matters most: Use full-fat sharp cheddar that you shred yourself for the best melting and flavor
Room temperature is key: Let the casserole rest 5-10 minutes after baking—it firms up and slices better
Don’t skip: The mustard—it’s the signature ingredient that gives this dish its authentic Coney flavor

Essential Equipment

You’ll Need:

Large pot — For boiling pasta
Large skillet — 12-inch size for browning meat and building the chili
9×13-inch baking dish — Standard casserole size
Colander — For draining pasta
Wooden spoon — For breaking up meat and stirring

Nice to Have:

Cheese grater — For freshly shredding cheese
Aluminum foil — If making ahead or covering during baking
Mixing spoon or spatula — For combining everything evenly

How to Make Coney Chili Mac Casserole (Step-by-Step)

Step 1: Cook the Pasta to Al Dente

Bring a large pot of salted water to a rolling boil. Add the elbow macaroni and cook until just al dente—about 1-2 minutes less than package directions. The pasta will continue cooking in the oven, so you don’t want it too soft. Drain well and set aside. Pro tip: Toss the drained pasta with a tiny drizzle of oil to prevent sticking while you prepare the chili.

Step 2: Brown the Ground Beef with Onions

Heat a large skillet over medium-high heat and add the ground beef. Break it up with a wooden spoon as it cooks, creating small, bite-sized pieces. When the meat is about halfway browned (after 3-4 minutes), add the diced onion and continue cooking, stirring occasionally. Cook for 6-8 minutes total until the beef is completely browned with no pink remaining and the onions are soft and translucent. You’ll know it’s ready when the meat has developed some nice caramelized bits. If there’s excess grease, drain most of it, leaving about 1 tablespoon for flavor.

Step 3: Build the Flavorful Chili Base

Reduce heat to medium and add the minced garlic to the beef and onions. Stir for about 30 seconds until fragrant but not browned. Add the tomato paste, chili powder, cumin, smoked paprika (if using), salt, and pepper. Stir everything together and let it cook for 1-2 minutes to toast the spices and caramelize the tomato paste slightly—this deepens the flavor significantly. Pour in the tomato sauce, beef broth, and yellow mustard. Stir well to combine everything into a thick, savory chili sauce. Let it simmer for 2-3 minutes to meld the flavors. Pro tip: Taste and adjust seasoning now—this dish should be boldly flavored, not bland.

Step 4: Combine Pasta with Chili Mixture

Add the cooked, drained macaroni to the skillet with the chili. Stir everything together until every piece of pasta is thoroughly coated with the rich chili sauce. If you’re adding beans, fold them in now. The mixture should look saucy and cohesive, not dry. Pro tip: If it seems dry, add a splash more beef broth—the pasta will absorb liquid as it bakes.

Step 5: Layer in Casserole Dish with Cheese

Preheat your oven to 375°F (190°C). Lightly grease a 9×13-inch baking dish with cooking spray or butter. Spread half of the chili mac mixture evenly in the bottom of the dish. Sprinkle about ½ cup of shredded cheddar cheese over this layer. Add the remaining chili mac mixture on top and spread it evenly. Finally, top generously with the remaining 1-1½ cups of shredded cheese, covering the entire surface. Pro tip: Layering cheese in the middle adds extra gooeyness throughout the casserole.

Step 6: Bake Until Bubbly and Golden

Place the casserole in the preheated oven and bake uncovered for 20-25 minutes. You’ll know it’s done when the cheese on top is melted, bubbly, and turning golden brown around the edges. The edges should be slightly crispy and the center should be bubbling. Remove from the oven and let it rest for 5-10 minutes before serving—this resting time allows the casserole to set up so it doesn’t fall apart when you scoop it.

Step 7: Top and Serve Hot

Before serving, add your favorite toppings—sliced jalapeños, chopped scallions, a drizzle of yellow mustard, sour cream, or crushed tortilla chips for crunch. Scoop generous portions into bowls or onto plates and serve hot. Pro tip: A drizzle of yellow mustard on top really drives home that authentic Coney dog experience.

Expert Tips & Tricks

Temperature Matters: Baking at 375°F ensures the cheese melts perfectly and the edges get slightly crispy without drying out the casserole.

Don’t Rush the Spice Toasting: Cooking the chili powder and spices with the tomato paste for a minute or two before adding liquids releases their essential oils and creates deeper, more complex flavor.

The Secret to Bold Flavor: Don’t be shy with the seasonings—this dish should zing with chili spices and tangy mustard.

Common Mistake: Overcooking the pasta initially causes it to become mushy in the final casserole—always cook it 1-2 minutes less than al dente.

Test Kitchen Discovery: Letting the casserole rest for 5-10 minutes after baking makes it easier to serve and actually intensifies the flavors as everything settles.

Customization Ideas

Dietary Modifications:

Gluten-Free: Use gluten-free elbow macaroni and ensure all seasonings are certified gluten-free
Lower Fat: Use 93% lean ground beef or ground turkey, reduce cheese slightly, and use low-sodium broth
Vegetarian: Replace ground beef with plant-based meat crumbles or cooked lentils, and add extra beans

Flavor Variations:

Spicy Coney Chili Mac: Add diced jalapeños, cayenne pepper, or use pepper jack cheese for serious heat
Loaded Chili Mac: Top with crushed tortilla chips, sour cream, green onions, and hot sauce for a nachos-inspired version
Hot Dog Coney Style: Add sliced hot dogs along with (or instead of) ground beef for authentic chili dog texture
BBQ Coney Mac: Add a tablespoon of BBQ sauce to the chili mixture for smoky-sweet depth
Veggie-Packed: Stir in diced bell peppers, corn, or spinach for added nutrition

Serving Styles:

Classic Casserole: Serve family-style directly from the baking dish with toppings on the side
Individual Portions: Portion into ramekins before baking for personal-sized servings
Skillet Style: Make it in a large oven-safe skillet and serve directly from the pan

Storage & Meal Prep

Make Ahead:

Assemble the entire casserole up to 24 hours ahead, cover tightly with foil, and refrigerate
When ready to bake, add 5-10 minutes to the baking time if baking from cold
Cook and season the beef mixture up to 2 days ahead and store separately

Storing:

Fridge: Store leftovers covered in the baking dish or airtight container for up to 4 days
Freezer: Freeze unbaked or baked casserole (well-wrapped) for up to 3 months

Reheating for Best Results:

Reheat individual portions in the microwave for 2-3 minutes, or reheat the whole casserole covered with foil at 350°F for 20-25 minutes until heated through. Add a splash of broth or water if it seems dry—this revives the creamy texture. The flavors actually deepen after a day in the fridge, making leftovers exceptionally tasty.

What to Serve With Coney Chili Mac Casserole

Perfect Pairings:

Garlic bread or cheddar cornbread: Perfect for soaking up the cheesy chili goodness
Tangy coleslaw: Adds brightness and crunch that contrasts beautifully with the rich casserole
Simple green salad with vinaigrette: The acidity cuts through the richness perfectly

Complete the Meal:

Serve with roasted vegetables like broccoli, carrots, or corn on the cob for a balanced plate
Add potato chips or tortilla chips on the side for extra crunch
Pair with pickles and raw onions for authentic Coney dog condiments

Nutrition Facts (Per Serving)

Note: Calculated based on 6 servings with full-fat ingredients. Nutrition varies based on specific brands, portion sizes, and optional additions.

Your Questions Answered

Can I make this in a slow cooker instead?

Yes! Brown the meat and sauté the onions first, then combine everything (including cooked pasta) in the slow cooker. Top with cheese, cover, and heat on low for about 1 hour until the cheese melts.

What cheese works best for chili mac casseroles?

Sharp cheddar is classic—it adds bold flavor and melts beautifully. You can also try a Mexican blend or pepper jack for more spice, or add a little cream cheese or Velveeta for extra creaminess.

Can I add hot dogs to make it more authentic?

Absolutely! Slice hot dogs into rounds and either add them with the ground beef or use them instead of ground beef entirely for that true Coney dog experience.

Why did my casserole turn out dry?

This usually happens when the pasta is overcooked initially or there isn’t enough liquid in the chili mixture. Make sure your sauce is slightly loose before baking, and don’t skip the beef broth.

Can I freeze this casserole?

Yes! Assemble but don’t bake, wrap tightly with foil, and freeze for up to 3 months. Thaw overnight in the fridge before baking, adding 5-10 minutes to the baking time.

What makes this different from regular chili mac?

The signature yellow mustard and Coney-style seasonings give this dish that distinctive tangy, slightly sharp flavor that sets it apart from standard chili mac.

Recipe History & Cultural Context

The Coney dog is a Detroit and Midwest institution with roots in Greek and Macedonian immigrant communities who settled in the region in the early 1900s. These immigrants opened Coney Island restaurants serving their unique version of chili dogs—beef chili without beans, seasoned with a specific blend of spices including mustard, topped with raw onions and yellow mustard on a steamed bun.

The term “Coney” itself is a nod to New York’s Coney Island, but Detroit-style Coney dogs evolved into their own distinct regional specialty with a devoted following. The chili used on Coney dogs is different from Texas-style chili—it’s finer textured, tangy from mustard, and specifically designed to top hot dogs rather than stand alone.

This casserole represents the brilliant home cooking tradition of taking beloved regional flavors and transforming them into practical, family-friendly dishes. By combining Coney-style chili with mac and cheese—another ultimate comfort food—home cooks created something that captures the nostalgic essence of those classic diners while being easier to make for a crowd. It’s comfort food that tells a story, honoring immigrant culinary traditions while adapting to modern American family meals.

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