If you love dishes that bring comfort and bold flavors together in one unforgettable bite, you are going to adore this Cowboy Pie (Leftover Chili Pie) Recipe. It takes smoky sausage chili, hearty pinto beans, creamy mash, and a melty cheddar topping to a whole new level of satisfying. Perfect for turning leftover chili into a totally fresh meal, this pie offers a glorious balance of smoky, savory, and tangy notes, crowned with golden, bubbling cheese. Whether it’s a cozy weeknight dinner or a lazy weekend treat, this Cowboy Pie is pure comfort food magic.

Ingredients You’ll Need
The beauty of this recipe lies in its simplicity. Each ingredient plays a key role in creating a dish that’s rich in texture, layered in flavor, and visually inviting. From the smoky chili to the creamy mash, these essentials come together effortlessly.
- ⅓ batch smoky sausage chili: This forms the flavorful base loaded with smoky, meaty goodness.
- 2 x 400g cans pinto beans, drained: Pinto beans add a creamy texture and hearty protein boost.
- 1-2 tablespoons barbecue sauce (Heinz Sticky Barbecue Sauce): Adds a sweet and tangy kick that elevates the chili flavor.
- 2 x 400g packs ready-made mash, microwaved for 2 minutes: Creamy mashed potatoes create the perfect soft topping that contrasts the chili.
- 50g mature cheddar, grated: Melts beautifully to give a golden, cheesy crust with a sharp flavor.
- Fresh coriander leaves to serve: A fresh, herbal finish that brightens every bite.
How to Make Cowboy Pie (Leftover Chili Pie) Recipe
Step 1: Preheat Your Oven
Start by heating your oven to 200°C (180°C fan) or gas mark 6. This ensures the pie will bake evenly, getting that perfectly golden, bubbling top.
Step 2: Warm the Chili and Beans
In a medium saucepan over medium heat, combine the smoky sausage chili and the drained pinto beans. Stir occasionally, letting them warm through until steaming hot. Then, add 1 to 2 tablespoons of barbecue sauce to infuse a lovely tang and sweetness. Always taste at this stage and adjust seasoning if needed—it’s the foundation of flavor for your pie.
Step 3: Assemble the Pie
Pour the warm chili and bean mixture into a 1.5-liter ovenproof dish. Next, layer on your warmed mashed potatoes evenly over the top. The softness of the mash contrasts wonderfully with the spicy chili below. Finally, sprinkle the grated mature cheddar cheese over the mash, which will melt and crisp beautifully as the pie bakes.
Step 4: Bake Until Golden and Bubbling
Place your dish in the oven and bake for 45 minutes. By the end, you’ll have a rich, golden crust bubbling with cheesy goodness. This step is what truly transforms the pie into something special and comforting. Once done, sprinkle fresh coriander leaves over the top for a burst of fresh herbal flavor.
How to Serve Cowboy Pie (Leftover Chili Pie) Recipe

Garnishes
Fresh coriander leaves are a classic, but for an extra pop, try a dollop of sour cream or a few slices of fresh avocado. These additions add cool creaminess that complements the smoky, spicy flavors beautifully.
Side Dishes
Since the Cowboy Pie is already wonderfully hearty, light sides like a crisp green salad with tangy vinaigrette or steamed seasonal veggies balance the meal well. For a bit of crunch, oven-roasted corn on the cob or garlic bread also make excellent companions.
Creative Ways to Present
If you’re serving guests or looking to impress, try scooping portions into individual ramekins before baking. This not only looks charming but helps with portion control. Another fun idea is to serve the pie alongside a spread of pickled jalapeños or hot sauce for those who love an extra kick.
Make Ahead and Storage
Storing Leftovers
Leftover Cowboy Pie can be stored in an airtight container in the fridge for up to 3 days. The flavors actually deepen over time, making it perfect for next-day lunches or dinners.
Freezing
This recipe freezes well if you want to prep ahead or save portions for later. Freeze in individual airtight containers or wrap the whole dish tightly. Thaw overnight in the fridge before reheating.
Reheating
To reheat, place your portion in the oven at 180°C (160°C fan) for about 20 minutes or until heated through and bubbling. You can also reheat in a microwave, though the oven helps maintain a nice crisp top.
FAQs
Can I use other types of chili for this recipe?
Absolutely! While smoky sausage chili works beautifully, you can substitute with beef chili, chicken chili, or even a vegetarian chili to customize the pie to your taste.
What if I don’t have ready-made mash?
No problem at all. You can easily make your own mashed potatoes from scratch using boiled potatoes, butter, and milk. The fresh mash will be just as delicious.
Is it okay to add more cheese or different cheese?
Yes! Feel free to increase the cheese quantity or experiment with other varieties like Monterey Jack or smoked cheddar for new flavors.
Can this recipe be made gluten-free?
Definitely! Just ensure your barbecue sauce is gluten-free and use gluten-free instant mash or homemade mashed potatoes without any flour or additives.
What can I serve if I want this dish for a party?
For parties, making individual mini Cowboy Pies in muffin tins works wonders. You can also pair with dips like guacamole, salsa, or a chilled bean salad to keep things fresh and festive.
Final Thoughts
This Cowboy Pie (Leftover Chili Pie) Recipe truly transforms simple ingredients into a comforting, crave-worthy meal that’s perfect any time you have leftover chili on hand. It’s easy to make, endlessly customizable, and always a crowd-pleaser. I can’t wait for you to try it and enjoy that perfect harmony of smoky, cheesy, and creamy flavors in every bite!
Print
Cowboy Pie (Leftover Chili Pie) Recipe
- Prep Time: 10 minutes
- Cook Time: 45 minutes
- Total Time: 55 minutes
- Yield: 4 to 6 servings
- Category: Main Course
- Method: Baking
- Cuisine: American
Description
Cowboy Pie is a hearty and comforting dish made with smoky sausage chili mixed with pinto beans and barbecue sauce, topped with creamy mashed potatoes and melted cheddar cheese. Baked until golden and bubbling, this leftover chili pie transforms simple ingredients into a satisfying meal perfect for family dinners.
Ingredients
Chili and Bean Mixture
- ⅓ 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
Garnish
- Fresh coriander leaves to serve
Instructions
- Preheat the Oven: Heat the oven to 200°C (180°C fan, gas mark 6) to prepare for baking the pie.
- Warm Chili and Beans: In a medium saucepan, combine the smoky sausage chili and drained pinto beans. Warm over medium heat until the mixture is steaming hot. Stir in 1 to 2 tablespoons of barbecue sauce, then taste and season if necessary to balance the flavors.
- Assemble the Pie: Pour the warmed chili and bean mixture into a 1.5-liter ovenproof dish. Spread the microwaved mashed potatoes evenly over the top and sprinkle with the grated mature cheddar cheese.
- Bake the Pie: Place the dish into the preheated oven and bake for 45 minutes, or until the topping is golden brown and the pie is bubbling hot throughout.
- Garnish and Serve: Once baked, sprinkle fresh coriander leaves on top before serving to add a fresh, herby finish to the dish.
Notes
- You can adjust the barbecue sauce to taste depending on the sweetness or tanginess you prefer in the filling.
- Ready-made mashed potatoes save time but homemade mash would also work well.
- For a spicier version, consider adding chili flakes or hot sauce to the chili mixture before baking.
- Ensure the chili and beans mixture is hot before assembling to reduce baking time and ensure even cooking.
- This dish can easily feed 4 to 6 people depending on portion sizes.

