8 oz dry macaroni (1 2/3 cups measured in a 2 cup glass liquid measure. Note that this measure will only work for macaroni and probably not a larger pasta shape. Weighing is recommended.)
1/4 cup butter
1/3 cup all-purpose flour
3 cups whole milk
7 oz Good aged white crumbly cheddar crumbled
3 oz Another variety orange sharp cheddar or cold-packed cheddar grated or crumbled
1/2 tsp kosher salt little less if using table salt
1/4 tsp regular chili powder
1/8 tsp garlic powder
1/2 oz aged cheddar grated
1/4 tsp chipotle chili powder
Add water and a bit of salt to a large pot and place over high heat for the pasta. While it’s heating, prepare the cheese sauce.
For the cheese sauce: In a large saucepan, melt the butter over medium heat. Whisk in the flour and continue to whisk and cook for about 2 minutes.
Very slowly add the milk, a little at a time, whisking constantly. Once all the milk has been added, cook, stirring frequently until the sauce thickens, about 10 minutes. (Don’t rush this step. The mixture will not be thick, but will noticeably thicken after 8-10 minutes of cooking).
Remove the saucepan from the heat. Add the cheese, salt, chili powder and garlic powder. Stir until the cheese is melted and all the ingredients are incorporated, about 3 minutes. (If the cheese isn’t melted completely after about 3 minutes, you can put the pan back on low heat and stir until it is melted). Set aside for a minute.
Preheat oven to 350F (175C) with rack in the centre of the oven. Oil or butter an 8-inch square baking dish, an 8-inch cast-iron skillet or individual baking dishes.
When the pasta water is boiling, add the macaroni and cook for 2 minutes less than the package directions indicate. (The noodles will finish cooking in the sauce in the oven). When the pasta is cooked, drain and immediately rinse well with cold water. Make sure your pasta is well drained.
Add the cooked pasta and to the cheese sauce and mix gently, but thoroughly. (It might look like too much sauce or too little pasta, but trust me, it will all be good in the end).
Spoon or ladle the mixture into a prepared baking dish or individual dishes. Sprinkle the top of each with a bit of additional grated sharp cheddar cheese (you don’t need a lot here, as there is plenty in the sauce), then sprinkle with the chipotle chili powder.
Bake in the preheated 350F (175C) oven uncovered for 20 to 25 minutes, until the sauce has bubbled up around the edges and the top has a nice golden crust. Let sit for a few minutes before serving.