If you’re craving a warm, hearty, and utterly comforting meal that feels like a big, delicious hug, then you have to try this Coney Chili Mac Casserole Recipe. It effortlessly combines the savory goodness of chili beans, ground beef, and a blend of spices with tender elbow macaroni and melty cheddar cheese. Every bite bursts with flavor and texture, making it a perfect crowd-pleaser for family dinners or casual get-togethers. The creamy sour cream adds a smooth touch that ties everything together beautifully, ensuring this casserole will soon become a beloved staple in your kitchen.

Ingredients You’ll Need
Preparing this Coney Chili Mac Casserole Recipe is simple thanks to a handful of essential ingredients. Each component plays a unique role in delivering that signature blend of rich chili and luscious pasta, making the casserole hearty, flavorful, and irresistibly cheesy.
- 1 pound ground beef: Provides a rich, meaty base packed with savory flavor and protein.
- 1 onion, chopped: Adds a natural sweetness and aromatic depth when sautéed.
- 1 (15 oz) can chili beans, undrained: Brings the classic chili texture and hearty bean goodness right into the dish.
- 1 (15 oz) can tomato sauce: Offers a tangy, tangy richness that balances the spices.
- 1 (4 oz) can diced green chilies: Adds a mild kick and subtle green freshness to brighten things up.
- 1 (1 oz) packet chili seasoning mix: The secret blend of spices that gives the chili its signature warmth and flavor.
- 2 cups elbow macaroni, cooked and drained: The comfort-food staple that soaks up all the delicious chili juices.
- 1 1/2 cups shredded cheddar cheese: Melts into gooey perfection, creating that irresistible golden crust.
- 1/2 cup sour cream: Adds creamy richness and a slight tang to perfectly bind the casserole.
- 1 tablespoon olive oil: Used for sautéing the onions to tender, flavorful perfection.
- Salt and pepper to taste: Essential seasonings to balance and enhance all the flavors.
How to Make Coney Chili Mac Casserole Recipe
Step 1: Prepare your workspace and preheat the oven
Start by preheating your oven to 375°F (190°C) and grease a 9×13-inch baking dish. This ensures your casserole won’t stick and will bake evenly into that perfect golden bubbly finish.
Step 2: Sauté the onions
Heat olive oil in a large skillet over medium heat, then add the chopped onions. Cooking them for about 3 minutes until softened brings out their natural sweetness, which adds a subtle depth to the entire dish.
Step 3: Brown the ground beef
Add the ground beef to the skillet with the onions and cook until it’s browned all over. Make sure to break it up into small pieces so it cooks evenly and mixes wonderfully with the other ingredients later. Drain any excess fat for a leaner casserole.
Step 4: Simmer the chili base
Stir in the chili seasoning mix, chili beans with their liquid, tomato sauce, and diced green chilies. Bring this hearty mixture to a gentle simmer and cook for about 10 minutes, stirring occasionally to meld all those spicy, savory flavors together. Season with salt and pepper according to your taste.
Step 5: Combine with macaroni and cheese
In a large bowl, mix the cooked elbow macaroni with the chili mixture, sour cream, and 1 cup of shredded cheddar cheese. This blend brings creaminess and cheesy goodness right into every forkful.
Step 6: Assemble the casserole
Transfer the combined mixture into your prepared baking dish. Top it off with the remaining 1/2 cup of shredded cheddar cheese to create a bubbly, golden crust after baking.
Step 7: Bake to perfection
Bake in the preheated oven for 20 minutes until the cheese on top is melted and bubbly. Let the casserole sit for about 5 minutes before serving to allow it to set and cool slightly, making it easier to serve and even more enjoyable to eat.
How to Serve Coney Chili Mac Casserole Recipe

Garnishes
Enhance your serving with fresh, vibrant garnishes like chopped green onions, a sprinkle of chopped fresh cilantro, or a dollop of extra sour cream. These little accents add freshness, color, and an extra burst of flavor that complements the hearty casserole perfectly.
Side Dishes
Pair your casserole with a simple green salad tossed in a tangy vinaigrette or some garlic bread to scoop up every last bit of cheesy chili goodness. A side of steamed broccoli or roasted veggies also balances the meal with some light crunch and nutrition.
Creative Ways to Present
Try making individual portions in small ramekins for a fun, personalized twist at dinner parties or family meals. You can even serve this casserole inside bell peppers or large baked potatoes for a creative and eye-catching presentation that doubles the deliciousness.
Make Ahead and Storage
Storing Leftovers
Keep any leftovers in an airtight container in the refrigerator for up to 3 days. This casserole tastes even better the next day as the flavors have more time to mingle! Just be sure to cool it completely before sealing to preserve freshness.
Freezing
This Coney Chili Mac Casserole Recipe freezes beautifully. Portion it into freezer-safe containers and store for up to 3 months. When ready to eat, thaw overnight in the fridge before reheating. It’s a fantastic option for quick meals during busy weeks.
Reheating
Reheat leftovers in the oven at 350°F (175°C) until warmed through and the cheese bubbles again, about 15-20 minutes. Alternatively, microwave individual servings on medium power for 2-3 minutes, stirring halfway to ensure even heat.
FAQs
Can I use a different type of pasta in this recipe?
Absolutely! While elbow macaroni is traditional and perfect for soaking up the chili, you can substitute with other short pasta shapes like rotini, penne, or shells. Just make sure to cook them al dente before mixing to maintain texture after baking.
Is this casserole spicy?
The heat level is mild thanks to the diced green chilies and chili seasoning mix, making it friendly for most palates. If you prefer it spicier, you can add more chilies or a pinch of cayenne pepper to kick up the flavor.
Can I make this recipe vegetarian?
Yes! Replace the ground beef with plant-based ground meat alternatives or extra beans to maintain protein and texture. You can also add sautéed mushrooms or lentils for added umami and heartiness in your Coney Chili Mac Casserole Recipe.
What can I use instead of sour cream?
If you don’t have sour cream on hand, Greek yogurt is a fantastic substitute that adds similar creaminess and tang. Just make sure to use plain, unsweetened yogurt to keep the flavors balanced.
How do I know when the casserole is done baking?
You’ll want the cheese on top to be fully melted, bubbly, and slightly golden brown. The casserole should be hot throughout, so if you’re unsure, inserting a knife into the center should come out warm to the touch.
Final Thoughts
There is something so wonderfully satisfying about a dish like this Coney Chili Mac Casserole Recipe. It’s like a cozy blanket of flavors that warms you from the inside out. Whether you’re feeding a hungry family or craving a comforting solo dinner, this casserole hits all the right notes of cheesy, meaty, and creamy. Don’t hesitate to dive in and make it your own — it’s sure to become one of those recipes you return to time and again.
Print
Coney Chili Mac Casserole Recipe
- Prep Time: 15 minutes
- Cook Time: 30 minutes
- Total Time: 45 minutes
- Yield: 6 servings
- Category: Casserole
- Method: Baking
- Cuisine: American
Description
Coney Chili Mac Casserole is a hearty and comforting baked pasta dish featuring seasoned ground beef chili, tender elbow macaroni, creamy sour cream, and melted cheddar cheese. Perfect for a family dinner, this casserole combines bold chili flavors with cheesy goodness in a convenient one-dish meal.
Ingredients
Meat and Vegetables
- 1 pound ground beef
- 1 onion, chopped
- 1 (4 oz) can diced green chilies
Canned Goods & Seasonings
- 1 (15 oz) can chili beans, undrained
- 1 (15 oz) can tomato sauce
- 1 (1 oz) packet chili seasoning mix
- Salt and pepper to taste
Pasta & Dairy
- 2 cups elbow macaroni, cooked and drained
- 1 1/2 cups shredded cheddar cheese (divided)
- 1/2 cup sour cream
Other
- 1 tablespoon olive oil (for sautéing)
Instructions
- Preheat Oven and Prepare Dish: Preheat your oven to 375°F (190°C) and grease a 9×13-inch baking dish to prevent sticking.
- Sauté Onions: Heat 1 tablespoon olive oil in a large skillet over medium heat. Add the chopped onion and cook for about 3 minutes until soft and fragrant.
- Brown the Ground Beef: Add the ground beef to the skillet. Cook, stirring and breaking it apart with a spoon, until browned evenly. Drain any excess fat from the skillet.
- Simmer Chili Mixture: Stir in the chili seasoning mix, chili beans with their liquid, tomato sauce, and diced green chilies. Bring the mixture to a simmer and cook for 10 minutes, stirring occasionally. Season with salt and pepper to taste.
- Combine with Macaroni and Cheese: In a large bowl, mix the cooked elbow macaroni, chili mixture, sour cream, and 1 cup of shredded cheddar cheese. Stir until fully combined.
- Assemble Casserole: Transfer the combined mixture into the prepared baking dish. Sprinkle the remaining 1/2 cup shredded cheddar cheese evenly over the top.
- Bake the Casserole: Place the casserole in the preheated oven and bake for 20 minutes, or until the cheese is melted and bubbly. Allow it to cool for about 5 minutes before serving.
Notes
- For extra spice, add a pinch of cayenne pepper or hot sauce to the chili mixture.
- You can substitute ground turkey or chicken for a leaner protein option.
- Leftovers can be refrigerated for up to 3 days and reheated in the oven or microwave.
- If you prefer a thicker chili, drain some of the liquid from the chili beans before cooking.
- For a gluten-free version, use gluten-free pasta instead of elbow macaroni.

