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Kielbasa Sausage Cheesy Potato Casserole

Kielbasa sausage cheesy potato casserole with smoky layers of tender Yukon Gold potatoes and a smooth, glossy cheddar cheese sauce that bubbles and browns on top. Baked covered then uncovered at 375°F for fork-tender potatoes and a golden, slightly crispy finish.
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Prep Time 25 minutes
Cook Time 1 hour 5 minutes
resting 10 minutes
Total Time 1 hour 40 minutes
Servings: 8 servings
Course: Dinner
Cuisine: American
Calories: 640
Ingredients Equipment Method Notes

Ingredients
  

Casserole
  • 1.5 lb kielbasa sausage Sliced into ½-inch rounds.
  • 2 lb Yukon Gold potatoes Peeled and thinly sliced (about ¼ inch thick).
  • 1 yellow onion Thinly sliced.
  • 2 garlic Minced.
  • 1 tbsp olive oil
  • 0.5 tsp smoked paprika
  • 0.5 tsp black pepper
  • 0.5 tsp salt
Cheese Sauce
  • 3 tbsp unsalted butter
  • 3 tbsp all-purpose flour
  • 2 cup whole milk
  • 1 cup chicken broth
  • 2 cup sharp cheddar cheese Shredded (divided).
  • 0.5 cup sour cream
  • 1 tsp Dijon mustard
  • 0.5 tsp garlic powder
  • 0.25 salt To taste.
  • 0.25 black pepper To taste.
Topping
  • 0.5 cup sharp cheddar cheese Shredded.
  • 2 tbsp fresh parsley or chives Chopped (for garnish).

Equipment

  • 1 cast iron skillet
  • 1 sheet pan
  • 1 Dutch oven
  • 1 stand mixer
  • 1 saucepan

Method
 

Prep and preheat
  1. Preheat your oven to 375°F (190°C). Grease a 9×13-inch baking dish with non-stick spray or butter and set aside.
Brown the kielbasa
  1. Heat olive oil in a large skillet over medium-high heat and add the sliced kielbasa. Cook for 3–4 minutes per side until the edges are golden and lightly caramelized, then remove to a plate.
Sauté the onion and garlic
  1. In the same skillet, add the sliced onion and cook over medium heat for 5 minutes until softened. Add the garlic and cook for 1 more minute until fragrant, then remove from heat.
Make the cheddar cheese sauce
  1. Melt butter in a medium saucepan over medium heat and whisk in the flour. Cook for 1 minute, stirring constantly, until the mixture turns pale golden.
  2. Gradually pour in the whole milk and chicken broth while whisking continuously to prevent lumps. Cook for 4–5 minutes, stirring, until thick enough to coat the back of a spoon.
  3. Remove from heat and stir in 1½ cups shredded sharp cheddar, sour cream, Dijon mustard, and garlic powder. Season with salt and black pepper until the sauce is smooth and glossy.
Layer and bake
  1. Layer half of the sliced Yukon Gold potatoes in the bottom of the baking dish, slightly overlapping. Season lightly with salt, smoked paprika, and black pepper.
  2. Spread the sautéed onions and garlic over the potatoes, then layer the browned kielbasa evenly on top. Arrange the remaining potato slices in an even layer over the sausage.
  3. Pour the cheese sauce slowly over everything, tilting the dish gently so it settles between the layers and coats the top. Sprinkle the remaining ½ cup of shredded sharp cheddar evenly over the top.
  4. Cover the dish tightly with foil and bake covered for 45 minutes at 375°F (190°C). Remove the foil and bake for an additional 20–25 minutes until the potatoes are fork-tender, the sauce is bubbling around the edges, and the top is golden and slightly crispy.
Rest and serve
  1. Remove the casserole from the oven and let it rest for 10 minutes before serving. Garnish with chopped fresh parsley or chives and serve hot.

Notes

For clean slicing and best structure, rest the casserole 10 minutes so the cheddar sauce sets before serving. Refrigerate leftovers in an airtight container for up to 3 days; reheat in a 350°F oven until hot throughout. Freezing: yes, freeze portions up to 2 months and reheat thawed. Swap option: use reduced-fat cheddar if you want a lighter cheese layer while keeping the same sauce method.