Classic Coney Chili Mac Casserole (Easy Bake!)

Introduction & Inspiration

Get ready for the ultimate comfort food mashup that brings together two beloved American classics: the hearty, savory flavors of a Coney Island chili dog and the cheesy goodness of macaroni and cheese, all baked into one incredibly satisfying casserole! This Coney Chili Mac Casserole features tender elbow macaroni tossed with a rich, homemade meat sauce seasoned with mustard and chili powder for that signature Coney flair, then generously topped with melted cheddar cheese. It’s simple, hearty, and oh-so-delicious.

My inspiration for this recipe comes from wanting to create a truly crowd-pleasing, family-friendly meal that’s packed with familiar, satisfying flavors but presented in an easy-to-make casserole format. It takes the best elements of chili mac and gives it that unique Coney Island twist with the mustard and chili powder seasoning.

This casserole is perfect for a cozy weeknight dinner, a potluck contribution, or anytime you’re craving a big pan of cheesy, meaty, pasta comfort. It’s straightforward to assemble and always a hit! It is a perfect recipe for a comforting family meal.

Nostalgic Appeal / Comfort Factor

Both Chili Mac and Coney Island Hot Dogs are deeply rooted in American comfort food traditions. Chili Mac, a classic one-pot wonder, evokes feelings of simple, hearty, and satisfying meals. Coney Island hot dogs, with their distinctive savory meat sauce, bring back memories of diners, amusement parks, ball games, and fun, unpretentious food.

This Coney Chili Mac Casserole beautifully combines these nostalgic comfort elements. You get the familiar, satisfying texture of baked macaroni and cheese, elevated by a savory ground beef sauce that has those characteristic tangy and spiced notes of a good Coney chili. The melted cheddar cheese on top is the crowning glory of comfort.

Making this dish is like preparing a warm, flavorful hug in a casserole dish – guaranteed to bring smiles and satisfy hearty appetites. A perfect comfort food casserole.

Homemade Focus (Chili Sauce & Assembly)

While this recipe is wonderfully straightforward and uses convenient pantry staples like canned tomato sauce, the homemade focus shines through in the creation of the flavorful Coney-style chili sauce and the assembly of the casserole itself. You’re starting by browning fresh ground beef from scratch, then simmering it with tomato sauce, beef broth, and a specific blend of seasonings including mustard and chili powder to develop that signature taste.

Cooking the elbow macaroni al dente and then combining it with your homemade chili sauce and cheddar cheese before baking are key homemade steps. You control the quality of the ground beef, the balance of seasonings in the sauce, and the amount of cheesy goodness.

It’s about taking simple, accessible ingredients and transforming them through thoughtful homemade preparation into a deeply satisfying and flavorful baked dish. The homemade Coney-style chili sauce is key.

Flavor Goal

The primary flavor goal is a harmonious blend of savory ground beef, tender elbow macaroni, and sharp cheddar cheese, all enveloped in a rich, tangy, and subtly spiced tomato-based sauce with the characteristic notes of mustard and chili powder found in Coney Island chili.

The ground beef should be flavorful and well-incorporated into the sauce. The macaroni, cooked al dente, should absorb the flavors of the sauce while maintaining a pleasant chew. The Coney-style chili sauce should be savory, with a tangy kick from the mustard, warmth from the chili powder, and a balanced tomato base. The cheddar cheese, both mixed in and melted on top, should provide a rich, gooey, savory counterpoint.

The overall experience should be a hearty, cheesy, saucy, and incredibly satisfying baked pasta dish that truly captures the essence of Coney chili mac. A perfect balance between flavour and texture.

Ingredient Insights

• Ground Beef (Lean): The savory meat base for the Coney-style chili sauce. Using lean ground beef (e.g., 90% lean) helps reduce excess grease. Browning it well is important for flavor.
• Cooked Elbow Macaroni: The classic pasta choice for mac and cheese and chili mac. Cook it al dente so it doesn’t become mushy during baking.
• Tomato Sauce (Canned): Provides the smooth tomato base for the chili sauce.
• Beef Broth: Adds moisture and savory depth to the chili sauce.
• Mustard (Prepared Yellow or Ground): A key ingredient for authentic Coney sauce flavor, providing a distinct tang. The recipe lists “mustard” and later “ground mustard” in a different recipe. This one says “1 tbsp mustard” which usually implies prepared yellow mustard in this context. I’ll clarify if ground, but assume prepared. Self-correction: The ingredients in other user recipes specify “ground mustard” when dry is intended. Here “1 tbsp mustard” strongly implies prepared yellow mustard, which is common in Coney sauce.
• Chili Powder: Adds classic chili flavor and warmth (not necessarily intense heat, depending on the blend).
• Shredded Cheddar Cheese (Divided): Provides sharp, savory flavor and excellent meltiness. Half is mixed into the casserole, and half is sprinkled on top.
• Optional Toppings (Diced Onions, Jalapeños, Sour Cream/Greek Yogurt, Crushed Tortilla Chips): Allow for customization and add layers of fresh flavor and texture, similar to topping a Coney dog or bowl of chili.

Tools Needed (as per original prompt):

• Large skillet
• 9×13-inch baking dish
• Mixing spoon or spatula
• Measuring cups and spoons
• Oven

Essential Equipment (Elaborated)

• Large Pot: For boiling the elbow macaroni.
• Colander: For draining the cooked macaroni.
• Large Skillet: Essential for browning the ground beef and simmering the chili sauce.
• 9×13-inch Baking Dish: Standard casserole size, perfect for these quantities. Needs to be greased.
• Mixing Spoon or Spatula: For breaking up beef, stirring sauce, and combining ingredients.
• Measuring Cups & Spoons:
• Can Opener:
• Cheese Grater (Optional): If shredding cheese from a block.

Ingredients

(Based on 1x column)

Coney Chili Mac Base:

• ▢ 1 lb ground beef (lean, e.g., 90%)
• ▢ 2 cups cooked elbow macaroni (from about 1 cup dry)
• ▢ 1 cup tomato sauce (canned)
• ▢ ½ cup beef broth
• ▢ 1 tbsp prepared yellow mustard
• ▢ 1 tbsp chili powder
• ▢ 1 cup shredded cheddar cheese, divided (½ cup for mix, ½ cup for topping)
• ▢ (Optional but Recommended: Salt and pepper to taste for chili sauce)
• ▢ (Implied for browning beef if not using a very non-stick pan: 1 tsp olive oil)

Optional Toppings:

• ▢ Diced fresh white or yellow onions
• ▢ Sliced fresh or pickled jalapeños
• ▢ Sour cream or plain Greek yogurt
• ▢ Crushed tortilla chips or Fritos

Step-by-Step Instructions

1. Prepare Oven, Dish, and Cook Macaroni:

• Preheat your oven to 350°F (175°C).
• Lightly grease a 9×13-inch baking dish with cooking spray or a thin layer of butter. Set aside.
• If you haven’t already, cook approximately 1 cup of dry elbow macaroni according to package directions in a large pot of salted boiling water until al dente (tender but still slightly firm to the bite).
• Drain the cooked macaroni well in a colander and set aside.

2. Brown the Ground Beef:

• In a large skillet over medium heat, cook the 1 pound of ground beef. (Add 1 tsp olive oil first if your skillet isn’t non-stick or if using very lean beef).
• Use a spatula or spoon to break the beef into small crumbles as it cooks. Continue stirring occasionally until it’s fully browned and no longer pink—this should take about 6–8 minutes.
• Carefully drain off any excess fat from the skillet.

3. Make the Coney Chili Sauce:

• To the skillet with the drained, browned beef, add the 1 cup of tomato sauce, ½ cup of beef broth, 1 tablespoon of prepared yellow mustard, and 1 tablespoon of chili powder. (Optional: Season with salt and pepper to taste here, keeping in mind cheese will add saltiness).
• Stir all the ingredients together until they are evenly combined.
• Bring the mixture to a gentle simmer. Reduce the heat to low and let it simmer for 5–10 minutes, stirring occasionally, until the sauce has thickened slightly and the flavors are aromatic and melded.

4. Combine with Macaroni and Half the Cheese:

• Turn off the heat under the skillet.
• Add the 2 cups of cooked elbow macaroni to the skillet with the Coney chili sauce.
• Add half of the shredded cheddar cheese (½ cup) to the mixture.
• Stir everything together gently but thoroughly until the macaroni and cheese are evenly coated with the sauce and the mixture is creamy.

5. Transfer to Baking Dish and Top:

• Spoon the entire macaroni, chili, and cheese mixture into your prepared 9×13-inch baking dish.
• Spread it into an even layer using your spatula or spoon.
• Sprinkle the remaining half of the shredded cheddar cheese (½ cup) evenly across the top of the casserole.

6. Bake:

• Place the baking dish, uncovered, in the preheated oven.
• Bake for 20–25 minutes.
• The Coney Chili Mac Casserole is done when it is bubbling at the edges, heated through completely, and the cheese on top has melted into a beautiful golden crust.

7. Rest and Serve:

• Let the casserole rest on a wire rack for about 5-10 minutes before serving. This allows the sauce to set slightly and makes it easier to serve neat portions.
• Garnish with your choice of optional toppings—diced fresh onions, sliced fresh or pickled jalapeños, a dollop of sour cream or plain Greek yogurt, or crushed tortilla chips for a crunchy finish.
• Slice into squares and serve hot. Enjoy this ultimate comfort food!

Troubleshooting

• Casserole Watery: Pasta wasn’t drained well enough; tomato sauce or beef broth was very thin; or didn’t simmer sauce long enough before adding pasta. Ensure pasta is thoroughly drained. Simmer sauce until slightly thickened. Resting after baking helps.
• Casserole Dry: Not enough sauce for the amount of pasta; pasta was overcooked initially and absorbed too much liquid; or baked too long uncovered. Ensure adequate sauce. Cook pasta only to al dente.
• Pasta Mushy: Overcooked pasta initially, or baked for an excessive amount of time. Cook pasta al dente.
• Meat Greasy: Didn’t use lean ground beef, or didn’t drain fat thoroughly enough after browning. This is a crucial step.
• Cheese Topping Burnt/Too Brown: Oven too hot, or top oven rack too close to heating element. Bake on middle rack. If cheese browns too quickly before casserole is heated through, you can loosely tent with foil for the last few minutes.
• Flavor Bland: Needs more seasoning! Taste the chili sauce before adding pasta and adjust salt, pepper, mustard, or chili powder. The flavor of your tomato sauce and beef broth also makes a difference.

Tips and Variations

• Al Dente Pasta is Key: Cook your elbow macaroni (or other pasta shape) 1-2 minutes less than the package directs for the firmest result after baking, as it will continue to cook in the sauce.
• Drain Beef Thoroughly: Very important for preventing a greasy casserole.
• Resting Time: Allowing the baked casserole to rest for 5-10 minutes before slicing isn’t just for cooling; it helps the portions hold together much better.
• Mustard Magic: Prepared yellow mustard is classic for Coney sauce, but a teaspoon of dry ground mustard could also be used for a slightly different tang.
• Cheese Choices: While cheddar is great, feel free to use a Colby Jack blend, Monterey Jack, or even add a layer of Velveeta slices under the cheddar for ultra-creamy melt like some chili macs.
• Add Beans: For a more traditional “chili mac” feel (though not classic “Coney”), stir in a can of rinsed and drained kidney beans or pinto beans along with the macaroni.
• Vegetable Boost: Sauté some diced green bell pepper or celery along with the onion and ground beef for extra vegetables in the chili sauce.
• Spice it Up: Use a spicier chili powder, add a dash of cayenne pepper or your favorite hot sauce to the chili sauce, or top with plenty of fresh or pickled jalapeños.
• Different Pasta Shapes: Penne, rotini, medium shells, or even cavatappi (as suggested in original ingredient notes) would all work well to capture the delicious sauce.

Serving and Pairing Suggestions

• Serve Hot & Bubbly: Best enjoyed warm from the oven (after a brief rest!).
• Main Course Comfort: A hearty and satisfying main dish perfect for family dinners.
• With Garlic Bread or Cornbread: Ideal for soaking up any extra delicious chili sauce!
• With a Simple Green Salad: A crisp salad with a light vinaigrette or a creamy coleslaw provides a nice fresh contrast to the richness of the casserole.
• Potluck Perfect: Easy to transport (in the dish) and always a massive hit at gatherings. Make sure to keep it warm.

Nutritional Information

(Note: Estimated, per serving, assuming 8-10 servings from a 9×13 pan. This is a hearty comfort food dish.)

• Calories: 400-550+
• Fat: 20-35g+
• Saturated Fat: 10-18g+
• Cholesterol: 60-90mg+
• Sodium: 800-1200mg+ (Tomato sauce, cheese, and ground beef contribute significantly)
• Total Carbohydrates: 30-40g+ (Mostly from pasta)
• Dietary Fiber: 2-4g+
• Sugars: 4-8g+ (from tomato sauce, onion)
• Protein: 20-30g+

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Recipe Summary and Q&A

Summary: This Coney Chili Mac Casserole starts by browning lean ground beef in a large skillet. Tomato sauce, beef broth, prepared mustard, and chili powder are stirred in and simmered to create a Coney-style chili sauce. Cooked al dente elbow macaroni and half of the shredded cheddar cheese are folded into this sauce. The mixture is then transferred to a greased 9×13-inch baking dish and topped with the remaining shredded cheddar cheese. The casserole is baked uncovered at 350°F for 20-25 minutes until heated through and the cheese is melted and bubbly. It’s rested briefly before serving with optional toppings like diced onions, jalapeños, sour cream, or crushed tortilla chips.

Q&A:

• Q: What makes it a “Coney” Chili Mac?
  • A: The “Coney” part typically refers to the style of chili sauce used on Coney Island hot dogs, which often includes ingredients like mustard, chili powder, and sometimes a specific blend of other spices, and is usually a beanless meat sauce (though this is a chili mac, not strictly a hot dog topping). The mustard and chili powder in this sauce give it that characteristic tangy, spiced flavor.
• Q: Can I use a different type of pasta if I don’t have elbow macaroni?
  • A: Yes, absolutely! Other sturdy pasta shapes that are good at holding sauce work well, such as penne, rotini, medium shells, or cavatappi. Cook according to package directions until al dente.
• Q: Can I assemble this casserole ahead of time?
  • A: Yes, you can assemble the entire casserole (up to the final cheese topping, or even with it), cover it tightly with foil or plastic wrap, and refrigerate it for up to 24 hours before baking. You may need to add about 10-15 minutes to the baking time if baking directly from cold.
• Q: How do I prevent the casserole from being too dry or too watery?
  • A: For dryness, ensure you use enough sauce to generously coat the pasta and beef mixture, and don’t overbake it. For wateriness, make sure your pasta is well-drained after cooking, and allow the chili sauce to simmer and thicken slightly before combining. Letting the baked casserole rest for 5-10 minutes before serving also helps the sauce set and prevents it from seeming too watery when first cut.