Let’s assemble and bake this delicious Coney Chili Mac Casserole:

1. Preheat Oven and Prepare Baking Dish:

• 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.

2. Cook Macaroni (If not already cooked):

• If you haven’t already, bring a large pot of lightly salted water to a boil. Cook about 1 cup of dry elbow macaroni according to package directions until al dente. Drain well and set aside. This should yield approximately 2 cups cooked.

3. Brown the Ground Beef:

• In a large skillet, cook the 1 lb of ground beef over medium heat. Use a spatula or wooden spoon to break it into small crumbles.
• Continue stirring occasionally until the beef is fully browned and no longer pink, typically about 6–8 minutes.
• Carefully drain off any excess fat from the skillet.

4. Make the Coney Chili Sauce:

• To the skillet with the browned and drained ground beef, add the 1 cup of tomato sauce, ½ cup of beef broth, 1 tablespoon of prepared mustard, and 1 tablespoon of chili powder. (Season with a little salt and pepper here if desired, keeping in mind cheese is salty).
• Stir all these ingredients together until evenly combined with the beef.
• Bring the mixture to a gentle simmer over low to medium-low heat. Let it simmer for 5–10 minutes, stirring occasionally, allowing the sauce to thicken slightly and the flavors to meld.

5. Combine with Macaroni and Cheese:

• Turn off the heat under the skillet.
• Add the 2 cups of cooked elbow macaroni to the skillet with the beef and chili sauce mixture.
• Add half of the shredded cheddar cheese (½ cup) to the skillet.
• Stir gently until the macaroni and cheese are evenly coated with the sauce and the cheese is beginning to melt into the mixture, making it creamy.

6. Transfer to Baking Dish and Top:

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

7. Bake:

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

8. Rest and Serve with Toppings:

• Carefully remove the hot casserole from the oven. Let it rest for about 5 minutes before serving. This allows the casserole to set slightly, making it easier to serve.
• Slice into squares or scoop onto plates.
• Garnish individual servings with your choice of optional toppings, such as diced fresh onions, sliced jalapeños, a dollop of sour cream or plain Greek yogurt, or a sprinkle of crushed tortilla chips for a crunchy finish. Enjoy!

A hearty, cheesy, and flavorful casserole ready to be devoured!