01 -
Set oven temperature to 375°F (190°C) to prepare for baking.
02 -
Boil elbow macaroni in salted water until just al dente, drain and set aside.
03 -
Render bacon in a skillet until crisp, drain on paper towels, then crumble into small pieces.
04 -
In a skillet, brown ground beef over medium heat. Season with kosher salt, black pepper, garlic powder, smoked paprika, and brown sugar. Stir in BBQ sauce and cook until meat is fully coated and heated through.
05 -
Melt butter in a heavy-bottomed saucepan over medium heat. Whisk in flour and cook for 2 minutes without browning. Gradually add warm milk, whisking constantly to prevent lumps.
06 -
Remove sauce from heat and fold in the shredded sharp cheddar, Gruyère, Monterey Jack, and Parmesan cheeses until fully melted and smooth, stirring gently to maintain creaminess.
07 -
In a large mixing bowl, layer the cooked macaroni followed by a thin spread of BBQ sauce, then evenly distribute crumbled bacon and the seasoned ground beef. Pour the cheese sauce over all, ensuring it fills gaps for balanced flavor.
08 -
Transfer mixture into a greased 9x13 inch ceramic casserole dish. Bake uncovered in preheated oven for 25 to 35 minutes until the top is golden brown and cheese is bubbling.
09 -
Insert a knife into the center to confirm it is hot throughout. Let rest for 5 minutes before serving to enhance flavor melding.