Smoked Mac and Cheese Bacon Cups build six edible bacon bowls, fill them with pasta in a four-cheese sauce, and finish each one with seasoned buttery crumbs. The smoker contributes flavor at two stages: first while the bacon forms around an inverted muffin tin, and again when the filled cups bake in a foil pan.
The recipe takes about 30 minutes to prepare and 60 minutes to cook, for a 90-minute total. Success depends on forming exactly six sturdy cups from 12 bacon strips, cooking pasta one minute short of its package direction, and keeping the cheese sauce smooth.
Ingredients for Six Bacon Cups
For the cups, use exactly 12 strips bacon and 1 tablespoon sweet BBQ rub. The macaroni requires 16 ounces small pasta shells or elbow macaroni, 6 tablespoons unsalted butter, ½ cup all-purpose flour, and 5½ cups whole milk.
The sauce combines 2 cups shredded smoked Gouda, 2 cups shredded smoked cheddar, 1 cup grated Parmesan, and 1 cup shredded mozzarella. For the topping, separately measure 2 tablespoons melted unsalted butter, ¾ cup bread crumbs, and 1 tablespoon all-purpose seasoning or BBQ rub.
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How to Make Smoked Mac and Cheese Bacon Cups
- Preheat the grill or smoker to 350°F. Turn a muffin tin upside down.
- For each of six cups, cut one bacon strip in half and cross the pieces over a muffin well. Wrap a second whole strip around its sides with overlapping ends. Season all cups with 1 tablespoon sweet BBQ rub.
- Smoke for 45 to 55 minutes, until cooked but not overly crisp. Cool, remove carefully, and set aside.
- Mix 2 tablespoons melted butter, ¾ cup crumbs, and 1 tablespoon seasoning.
- Melt 6 tablespoons butter over medium heat, whisk in ½ cup flour for about 1 minute, then slowly whisk in 5½ cups milk. Cook until bubbling and thick. Remove from heat and stir in all four cheeses.
- Cook pasta one minute less than its package direction, drain, and coat with sauce. Fill six bacon cups, add crumbs, place in a foil pan, and smoke about 30 minutes until golden.
For storage details after serving, the USDA leftovers and food safety guidance.
Form the Bacon Around an Inverted Tin
Turn the muffin pan upside down so six raised wells become molds. For the first cup, cut one bacon strip into two equal pieces and lay them across the crown in an X. Take a second whole strip and wrap it around the side, overlapping its ends to close the ring.
Repeat the same construction five more times, using exactly two strips per cup and all 12 strips in total. The crossed pieces form the base, while the wrapped strip reinforces the wall. Sprinkle the measured sweet BBQ rub over the assembled bacon before it enters the smoker.
If you enjoy this recipe, you may also like Hot Seafood Dip.
Smoke Until Sturdy, Not Brittle
Cook the inverted bacon cups at exactly 350°F for 45 to 55 minutes. They should be cooked through and firm enough to hold their shape, but the source method cautions against making them too crispy. Brittle bacon is harder to remove and may crack when filled.
Let the pan cool enough to handle, then loosen the cups carefully rather than pulling on one strip. Work around each edge and lift evenly. If a cup still feels flexible, support its base as it comes off the mold and place it upright while it settles.
Prepare the Crumb Topping Separately
Combine exactly 2 tablespoons melted unsalted butter, ¾ cup bread crumbs, and 1 tablespoon all-purpose seasoning or BBQ rub in a small bowl. Stir until the butter is distributed and the crumbs look evenly moistened rather than clumped in wet patches.
Set this mixture aside while preparing the sauce and pasta. Keeping it separate protects its texture. It should be scattered on top of the filled cups immediately before the final 30-minute smoke, where the butter helps it turn crisp and golden.
Build a Smooth Roux and Milk Base
Melt 6 tablespoons unsalted butter in a saucepan over medium heat. Add exactly ½ cup flour and whisk constantly for about 1 minute. The mixture becomes thick and paste-like; that brief cooking removes raw flour flavor without darkening the roux.
Pour in the 5½ cups whole milk gradually while whisking. A slow addition lets the roux disperse instead of forming lumps. Continue cooking over medium heat, whisking periodically and scraping the bottom, until the sauce begins to bubble and becomes noticeably thick.
Melt Four Cheeses Off the Heat
Remove the thickened milk base from direct heat before adding cheese. Stir in all 2 cups smoked Gouda, 2 cups smoked cheddar, 1 cup Parmesan, and 1 cup mozzarella. Add in portions and stir until the sauce is completely smooth before introducing more.
Off-heat melting reduces the risk that cheese will separate or become grainy. The smoked Gouda and cheddar supply the dominant smoky flavor, Parmesan adds savory depth, and mozzarella contributes a creamy pull. Keep the finished sauce nearby while the pasta drains.
Undercook the Pasta by One Minute
Bring a large pot of water to a boil and cook all 16 ounces small shells or elbow macaroni for exactly one minute less than the package states. This deliberate undercooking leaves the pasta firm enough to absorb sauce and withstand another 30 minutes of heat.
Drain thoroughly, return the pasta to its pot, and immediately pour in the warm cheese sauce. Fold until every shell or elbow is coated. Do not rinse the pasta, because its surface starch helps the rich sauce cling.
Fill and Finish All Six Cups
Stand the six bacon cups upright in a foil pan. Spoon the sauced pasta into each opening and fill them generously but without pressing hard enough to split the bacon. Divide the prepared crumb mixture evenly over all six tops.
Return the foil pan to the 350°F grill or smoker and bake for about 30 minutes. The topping should become golden and crisp, and the macaroni should be hot throughout. Since all components are already cooked, this stage melds flavors and sets the topping rather than requiring aggressive heat.
Serving and Make-Ahead Planning
Serve the cups hot from the smoker while the cheese remains gooey and the crumb layer is crisp. Each is rich and substantial, so one cup makes an appropriate serving. Use a small spatula or tongs to transfer them without squeezing the bacon walls.
The bacon cups may be formed and cooked ahead, then refrigerated until filling time, as the source recipe advises. Let them remain cool while making fresh macaroni and sauce. Complete the filling and final smoke close to serving so the pasta stays creamy.
Troubleshooting Structure and Sauce
If a bacon cup collapses, it may have been removed before firm, wrapped without enough overlap, or cooked with slices too thin to support the filling. Preserve the X-shaped base and surrounding band, and cool before lifting from the tin.
A lumpy sauce usually comes from adding milk too quickly, while graininess can come from boiling after the cheese is added. Whisk milk gradually, thicken it before cheese, then remove the pan from heat. If pasta seems dry, verify the full 5½ cups milk and avoid cooking it beyond the stated package-minus-one-minute stage.
Conclusion
Form six cups on an inverted muffin tin using two bacon strips each; season and smoke at 350°F for 45 to 55 minutes. Make seasoned crumbs and a four-cheese sauce, cook pasta one minute short, and combine. Fill the cups, top with crumbs, and smoke in a foil pan about 30 minutes.
Frequently Asked Questions
- → How many bacon cups does this recipe make?
It makes exactly six cups, using two of the 12 bacon strips for each one.
- → How long should the empty bacon cups smoke?
Smoke them at 350°F for 45 to 55 minutes, until cooked and sturdy but not excessively crisp.
- → Why cook the pasta one minute short?
The pasta continues cooking during the final 30-minute smoke, so undercooking it slightly prevents a soft texture.
- → Can the bacon cups be prepared ahead?
Yes. Cook and refrigerate the empty cups, then fill them with freshly prepared macaroni and complete the final smoke near serving time.