. 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!