Grilled Mac and Cheese Sandwich

11 steps · 1h 17m total

1. 01

   Boil Macaroni

   Bring a medium saucepan of generously salted water (think seawater) to a boil. Add the pasta and cook, stirring occasionally, until al dente, about 8 to 10 minutes, or according to the package directions. The pasta should be tender but still have a slight chew.
2. 02

   Whisk Dry Ingredients

   While the pasta cooks, grab a small bowl and whisk together the flour, mustard powder, garlic powder, salt, black pepper, and cayenne pepper. Set this aside.
3. 03

   Make the Roux

   Drain the pasta in a colander. You don't need to wash the pan; just place it back over low heat and add the butter. Once the butter has melted, whisk in your prepared flour mixture.

   Continue to cook, whisking frequently, until the mixture starts to brown slightly and gives off a pleasant, nutty aroma, which should take about 1 minute. Keep a close eye on it to prevent scorching.

4. 04

   Finish Mac and Cheese

   Slowly whisk the milk and cream into the flour mixture until everything is thoroughly combined. Cook, whisking constantly, until the sauce is heated through and just begins to thicken, about 2 minutes. Remove the pan from the heat.

   Gradually add the Monterey Jack cheese, stirring constantly with a wooden spoon or silicone spatula until all the cheese has melted into the sauce. Finally, stir in the drained, cooked pasta.

5. 05

   Chill Mac and Cheese

   Line a 9-by-13-inch (23-by-33-centimeter) rimmed baking sheet with parchment paper or aluminum foil. Lightly coat the paper or foil with nonstick cooking spray or a thin layer of butter.

   Pour the warm mac and cheese onto the prepared baking sheet and spread it evenly with a spatula. Take another piece of parchment paper, coat it with cooking spray or butter, and place it, oiled or buttered side down, directly onto the surface of the mac and cheese. Refrigerate until the mac and cheese is completely cool and firm, about 1 hour.

6. 06

   Heat Skillet

   Heat a large cast-iron or nonstick skillet over medium-low heat.
7. 07

   Make Garlic Butter

   In a small bowl, stir together the 4 tablespoons (55 grams) of butter and garlic powder until they are well blended.
8. 08

   Cut Mac and Cheese

   Remove the chilled mac and cheese from the refrigerator and peel off the top layer of parchment paper. Carefully cut the slab into 8 equal pieces; each piece will form the core of one grilled mac and cheese sandwich.

   If you're not making all the sandwiches at once, you can store individual portions in a double layer of resealable plastic bags and refrigerate them for up to 3 days or freeze for up to 1 month.

9. 09

   Assemble Sandwiches

   Spread 3/4 teaspoon of the garlic butter on one side of each bread slice. Place half of the bread slices, buttered-side down, on a clean cutting board. Top each with one slice of Cheddar cheese, then one piece of the chilled mac and cheese (you can slide your hand or a spatula under each mac and cheese piece and flip it onto the bread). Place one slice of Colby Jack on top of the mac and cheese, then finish with the remaining bread slices, buttered-side up.
10. 10

    Grill Sandwiches

    Using a wide spatula, carefully place as many sandwiches as will fit comfortably in the hot skillet without crowding. Cover the skillet and cook until the bottoms are nicely browned, about 4 minutes. Flip the sandwiches and cook for about 4 minutes more, until the second sides are browned, both cheeses are melted, and the mac and cheese filling is heated through.
11. 11

    Finish and Serve

    Repeat the grilling process with any remaining sandwiches. If you like, cut the finished sandwiches in half before serving.