Yields: 6-8 Servings
Prep Time: 20 minutes
Cook Time: 25 minutes
Total Time: 45 minutes

Ingredients

For the Pasta & Chicken:

1 pound elbow macaroni, cavatappi, or shells

2 cups cooked chicken, shredded or diced (rotisserie chicken works perfectly)

¾ cup your favorite BBQ sauce, plus more for serving

For the Cheese Sauce:

4 tablespoons unsalted butter

⅓ cup all-purpose flour

3 cups whole milk, warmed

1 teaspoon garlic powder

1 teaspoon onion powder

1 teaspoon dry mustard (or Dijon mustard)

½ teaspoon smoked paprika

Salt and black pepper, to taste

2 cups shredded sharp cheddar cheese

2 cups shredded Monterey Jack or Gouda cheese

For the Buttery Topping:

1 cup panko breadcrumbs

2 tablespoons unsalted butter, melted

2 tablespoons freshly grated Parmesan cheese

1 tablespoon chopped fresh parsley (optional)

 Instructions

Cook the Pasta and Prepare the Chicken

Bring a large pot of generously salted water to a boil. Add the pasta and cook according to package directions until al dente (firm to the bite). Reserve 1 cup of the starchy pasta water before draining. This liquid gold will be key to perfecting your sauce consistency later. Drain the pasta and return it to the pot.

In a separate bowl, toss the 2 cups of shredded cooked chicken with the ¾ cup of BBQ sauce until the chicken is evenly coated. Set this aside while you make the cheese sauce.

Create the Roux (The Foundation of the Sauce)

In a large, heavy-bottomed pot or Dutch oven, melt the 4 tablespoons of butter over medium heat. Once melted and foaming, whisk in the ⅓ cup of flour. Cook, whisking constantly, for about 1-2 minutes until the mixture (the roux) is bubbly and smells slightly nutty. Do not let it brown. This step cooks the raw flour taste out.

Whisk in the Milk for a Smooth Béchamel

Gradually pour in the warmed milk while whisking constantly to prevent any lumps from forming. Continue to whisk as the mixture comes to a gentle simmer. It will slowly thicken into a smooth, creamy white sauce known as a béchamel.

Season and Add the Cheese

Whisk in the garlic powder, onion powder, dry mustard, smoked paprika, salt, and pepper. Let the sauce simmer for another 2-3 minutes to allow the flavors to meld.

Reduce the heat to low. Gradually add the shredded cheddar and Monterey Jack cheeses, one handful at a time, whisking until each addition is completely melted and smooth before adding the next. Pro-Tip: Tossing your shredded cheese with a teaspoon of cornstarch can help prevent it from clumping and seizing.

Combine Pasta, Sauce, and BBQ Chicken

Pour the finished cheese sauce over the drained pasta in the large pot. Add a splash (about ¼ cup) of the reserved pasta water. Stir everything together until the pasta is beautifully coated. The starchy pasta water will help the sauce cling to the noodles and create a silky, cohesive texture.

Now, gently fold in the BBQ sauced chicken. You can either fully incorporate it or just swirl it through for beautiful ribbons of BBQ flavor.

 Prepare the Crispy Topping and Assemble

Preheat your oven’s broiler, or preheat the oven to 400°F (200°C).

In a small bowl, mix the panko breadcrumbs with the 2 tablespoons of melted butter and the grated Parmesan cheese until the crumbs are evenly moistened.

Transfer the mac and cheese mixture to a 9×13-inch baking dish or an oven-safe skillet. Spread it into an even layer. Sprinkle the buttery panko mixture evenly over the top.

Broil to Golden Perfection

Place the dish under the broiler (or in the hot oven) for 2-4 minutes, watching VERY closely, until the panko topping is golden brown and crispy. The broiler works quickly, so do not walk away!

Serve Immediately

Remove from the oven and let it rest for 5 minutes before serving. This allows the sauce to set slightly. Garnish with fresh parsley if desired, and serve with extra BBQ sauce on the side for those who want an extra kick.

Chef’s Notes & Recipe Variations

The Cheese Blend is Key: Using a blend of a strong cheese (like sharp cheddar) for flavor and a great melting cheese (like Monterey Jack, Gouda, or Fontina) for creaminess creates the perfect sauce. Pre-shredded cheese contains anti-caking agents that can make your sauce grainy; for the smoothest sauce, shred your own cheese from a block.

Warm Your Milk: Using warmed milk prevents the roux from cooling down too quickly, which helps it thicken smoothly and prevents lumps.

Customize the BBQ Flavor: Feel free to experiment with different BBQ sauces—a hickory-smoked sauce, a sweet and spicy one, or a coffee-infused variety can completely change the profile of the dish.

Add Vegetables: For a boost of nutrition and color, stir in 1 cup of thawed frozen peas, cooked broccoli florets, or sautéed diced onions and bell peppers along with the chicken.

Make it Spicy: Add a pinch of cayenne pepper to the cheese sauce or use a pepper Jack cheese in the blend.

Storage and Reheating

You can keep leftovers in the fridge for up to three days if you put them in an airtight container. To loosen the sauce, gently reheat in the microwave and toss in a little milk. To keep the topping from burning, you may alternatively reheat it in an oven at 350°F (175°C) for 15 to 20 minutes while covered with foil.

Before baking, this meal can be put together in advance, covered, and chilled for up to 24 hours. If you’re beginning from cold, you might need to extend the baking time by five to ten minutes.

Nutrition Information

Serving Size: 1/8 of the recipe

Calories: ~580

Total Fat: 25g

Saturated Fat: 14g

Cholesterol: 90mg

Sodium: 750mg

Total Carbohydrates: 58g

Dietary Fiber: 2g

Sugars: 15g

Protein: 30g

Dietary Note: This recipe is high in saturated fat and sodium. It contains gluten and dairy. For a gluten-free version, use gluten-free pasta and breadcrumbs. The high protein content comes from the chicken and cheese.