If you ever find yourself staring at a pot of leftover chili wondering how to transform it into something truly spectacular, the Cowboy Pie (Leftover Chili Pie) Recipe is your next go-to. This hearty dish takes smoky sausage chili and layers it with tender pinto beans, zesty barbecue sauce, and creamy mash, all baked to golden perfection under a blanket of melted mature cheddar. It’s like comfort food’s best friend showing up at your dinner table, turning humble leftovers into a celebration of bold flavors and cozy textures.

Ingredients You’ll Need
This recipe keeps things delightfully simple, but every ingredient plays a starring role in delivering the signature taste and perfect texture of the Cowboy Pie. From rich smoky sausage chili to creamy mashed potatoes and sharp cheese, each element blends beautifully to create layers of flavor and color.
- â…“ batch smoky sausage chili: This provides the hearty meat base full of smoky spices and depth.
- 2 x 400g cans pinto beans, drained: These add creaminess and a subtle earthiness, balancing the chili’s heat.
- 1-2 tablespoons barbecue sauce (Heinz Sticky Barbecue Sauce): The sweet and tangy notes brighten the filling and complement the chili perfectly.
- 2 x 400g packs ready-made mash, microwaved for 2 minutes: Quick and creamy, this forms a luscious, comforting topping.
- 50g mature cheddar, grated: Sharp and melty, it creates a irresistible golden crust.
- Fresh coriander leaves to serve: A fresh, herbal garnish that adds a final pop of color and flavor.
How to Make Cowboy Pie (Leftover Chili Pie) Recipe
Step 1: Preheat the Oven
Start by heating your oven to 200°C (180°C fan) or gas mark 6. This ensures it’s ready and hot enough to bake the pie to bubbly, golden perfection once assembled.
Step 2: Warm the Filling
In a medium saucepan over medium heat, combine your smoky sausage chili with the drained pinto beans. Stir gently and let the mixture heat through until you see steam rising—this helps the flavors meld beautifully.
Step 3: Add the Barbecue Sauce
Now it’s time to stir in one to two tablespoons of your favorite barbecue sauce. I love using Heinz Sticky Barbecue Sauce for its perfect balance of sweet and tangy. Taste the filling and adjust salt or spice if needed; this tangy kick really brings the pie alive.
Step 4: Assemble the Pie
Pour the warm chili and bean mixture into a 1.5-liter ovenproof dish. Next, dollop or carefully spread your microwaved mash over the top, creating a smooth and even layer. Finally, sprinkle the grated mature cheddar generously over the surface—this cheese layer is going to give you that irresistible golden crust.
Step 5: Bake to Perfection
Pop your assembled pie into the preheated oven and bake for around 45 minutes. You’re aiming for that bubbly filling peeking through and a beautifully browned, slightly crispy cheese topping that signals it’s ready to devour.
Step 6: Garnish and Serve
Once out of the oven, sprinkle fresh coriander leaves over the top for a bright, herbaceous finish. This small touch lifts the richness and adds a lovely freshness to each bite.
How to Serve Cowboy Pie (Leftover Chili Pie) Recipe

Garnishes
Fresh coriander is the classic choice here, adding a splash of color and cool herbal brightness. For an extra layer of decadence, a dollop of sour cream or a spoonful of guacamole pairs wonderfully, cooling down the smoky, spicy notes of the filling.
Side Dishes
This pie is a complete meal on its own, but you can serve it alongside a crisp green salad with a tangy vinaigrette or some roasted vegetables for added crunch and freshness. Cornbread or crusty bread also makes a cozy addition to help soak up all the flavorful juices.
Creative Ways to Present
For a fun twist, serve the Cowboy Pie in individual ramekins or small cast-iron skillets for single portions that look stunning on the plate. You can also turn the leftovers into stuffed peppers by filling halved bell peppers with the pie mixture and topping with mash and cheese before baking.
Make Ahead and Storage
Storing Leftovers
Leftover Cowboy Pie stores beautifully in an airtight container in the fridge for up to three days. The flavors continue to meld as it rests, making it even tastier the next day.
Freezing
If you want to save some for later, this pie freezes well. Cover tightly with foil or plastic wrap and store for up to three months. It’s a lifesaver when you need a comforting meal in a flash.
Reheating
Reheat leftovers in a preheated oven at 180°C (160°C fan) for 20-25 minutes or until piping hot throughout. For quicker reheating, microwave it covered for 2-3 minutes, though the oven method helps retain that lovely crisp cheese topping.
FAQs
Can I use other types of chili for this Cowboy Pie?
Absolutely! While smoky sausage chili adds incredible flavor, you can use any leftover chili you have on hand, whether beef, vegetarian, or even chicken chili. Just adjust seasoning to taste before assembling.
What if I don’t have ready-made mash?
No problem at all! You can make your own mashed potatoes from scratch or even use mashed sweet potatoes for a slightly sweeter, nutritious twist to the topping.
Is Cowboy Pie spicy?
The spice level depends on your chili and barbecue sauce choice. If you like it mild, opt for a milder barbecue sauce and chili. For more heat, use a hot chili and a spicier sauce. It’s very adaptable.
Can I prepare this pie ahead of time before baking?
Yes, you can assemble the pie in the baking dish, cover it tightly, and refrigerate for a few hours or overnight. When ready, just bake it as directed—add a few extra minutes if it comes straight from the fridge.
What alternatives are there to barbecue sauce?
If you don’t have barbecue sauce on hand, a splash of tomato ketchup mixed with a bit of smoked paprika and honey can mimic that sweet-smoky flavor. Worcestershire sauce or chipotle sauce also make great substitutes depending on your taste preference.
Final Thoughts
The Cowboy Pie (Leftover Chili Pie) Recipe turns everyday leftovers into a heartwarming, satisfying meal that fills your kitchen with inviting aromas and your belly with comfort. Once you try this, it will become your favorite way to enjoy chili all over again. Give it a go and savor every delicious bite with family or friends!
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Cowboy Pie (Leftover Chili Pie) Recipe
- Prep Time: 10 minutes
- Cook Time: 45 minutes
- Total Time: 55 minutes
- Yield: 4 servings
- Category: Main Course
- Method: Baking
- Cuisine: American
Description
Cowboy Pie is a hearty and comforting dish made from smoky sausage chili combined with pinto beans, topped with creamy mashed potatoes and mature cheddar cheese, then baked until golden and bubbling. Perfectly suited for using leftover chili, this rustic pie delivers a smoky, savory flavor with a touch of barbecue sauce and fresh coriander to brighten each bite.
Ingredients
Filling
- â…“ batch smoky sausage chili
- 2 x 400g cans pinto beans, drained
- 1–2 tablespoons barbecue sauce (Heinz Sticky Barbecue Sauce)
Topping
- 2 x 400g packs ready-made mashed potatoes, microwaved for 2 minutes
- 50g mature cheddar, grated
- Fresh coriander leaves to serve
Instructions
- Preheat the oven: Heat your oven to 200°C (180°C fan) or gas mark 6 to prepare it for baking the pie.
- Combine the filling: In a medium saucepan, mix the smoky sausage chili and drained pinto beans together. Warm the mixture over medium heat until it is steaming, then stir in 1 to 2 tablespoons of barbecue sauce. Taste and season with salt and pepper if needed.
- Assemble the pie: Pour the warm chili and bean mixture into a 1.5-liter ovenproof dish, spreading it evenly. Top generously with the warmed mashed potatoes and sprinkle the grated mature cheddar cheese over the surface.
- Bake the pie: Place the dish in the preheated oven and bake for 45 minutes, or until the topping is golden brown and bubbly.
- Garnish and serve: Remove from the oven and sprinkle fresh coriander leaves on top before serving for a burst of freshness.
Notes
- You can adjust the amount of barbecue sauce to suit your preferred level of smokiness and tang.
- Using ready-made mashed potatoes saves time, but homemade mash can be used for an even creamier topping.
- This dish is ideal for using up leftover chili to create a new hearty meal.
- For a vegetarian version, substitute the smoky sausage chili with a plant-based chili and ensure beans and mash are vegetarian-friendly.

