In a large skillet, cook ground beef over medium heat until browned.
Add onion and garlic; cook until soft.
Stir in tomato sauce, diced tomatoes, tomato paste, chili powder, cumin, paprika, salt, and pepper.
Simmer for 10–15 minutes, stirring occasionally, until thickened.
Prepare the cheesy pasta:
In a large bowl, combine cooked pasta with butter, milk, 1 ½ cups cheddar cheese, and mustard powder (if using).
Mix until cheese is mostly melted and pasta is coated.
Assemble the casserole:
Preheat oven to 375°F (190°C).
Spread half the cheesy pasta in a greased 9×13-inch baking dish.
Spoon chili mixture evenly over the top.
Layer the remaining pasta over the chili, then sprinkle with remaining cheese.
Bake:
Bake uncovered for 20–25 minutes, until bubbly and golden on top.
Serve:
Let rest 5–10 minutes before serving.
Garnish with green onions, bacon, or jalapeños if desired.
💡 Tips for Extra Flavor:
Stir in a splash of Worcestershire sauce or hot sauce into the chili for depth.
Substitute part of the cheddar with pepper jack for a spicy twist.
Leftovers reheat beautifully — this casserole tastes even better the next day!
Would you like me to share a slow-cooker version of this Coney Chili Mac Casserole — where everything simmers together and the cheese melts perfectly into the pasta?
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