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Kielbasa Sausage Cheesy Potato Casserole

Kielbasa sausage cheesy potato casserole made with browned kielbasa, thin-sliced Yukon Gold potatoes, and a smooth cheddar cheese sauce that bakes up golden and bubbly. Layered in a 9x13 baking dish for creamy, tender potatoes in every bite.
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Prep Time 20 minutes
Cook Time 1 hour 5 minutes
resting 10 minutes
Total Time 1 hour 35 minutes
Servings: 8 servings
Course: Dinner
Cuisine: American
Calories: 540
Ingredients Equipment Method Notes

Ingredients
  

Casserole Base
  • 1 lb kielbasa sausage
  • 2 lb Yukon Gold potatoes
  • 1 yellow onion
  • 2 cloves garlic
  • 1 tbsp olive oil
Cheese Sauce
  • 3 tbsp unsalted butter
  • 3 tbsp all-purpose flour
  • 2 cup whole milk
  • 0.5 cup sour cream
  • 2 cup sharp cheddar cheese shredded, divided
  • 0.5 tsp smoked paprika
  • 0.5 tsp garlic powder
  • 0.5 tsp onion powder
  • 0.5 tsp salt
  • 0.25 tsp black pepper
Topping
  • 0.5 cup sharp cheddar cheese reserved for topping
  • 2 tbsp fresh chives or parsley chopped for garnish

Equipment

  • 1 sheet pan
  • 1 cast iron skillet
  • 1 Dutch oven

Method
 

Prep and preheat
  1. Preheat your oven to 375°F (190°C) and lightly grease a 9×13-inch baking dish with cooking spray or butter.
  2. Arrange the sliced potatoes, kielbasa, onion, and garlic so they’re ready to layer.
Brown the kielbasa and sauté aromatics
  1. Heat olive oil in a skillet over medium-high heat, then add kielbasa in a single layer and cook 2–3 minutes per side until browned and caramelized; remove and set aside.
  2. In the same skillet, cook onion over medium heat for 4–5 minutes until softened and lightly golden.
  3. Add minced garlic and cook 1 minute, then remove from heat.
Make the cheddar cheese sauce
  1. In a medium saucepan, melt butter over medium heat, whisking in flour, and cook 1–2 minutes until lightly golden and nutty-smelling.
  2. Slowly pour in whole milk while whisking constantly to avoid lumps.
  3. Cook over medium heat for 4–5 minutes, stirring frequently, until thickened enough to coat the back of a spoon.
  4. Remove from heat and stir in sour cream, 1½ cups shredded sharp cheddar, smoked paprika, garlic powder, onion powder, salt, and black pepper until the cheese is fully melted and the sauce is smooth.
Layer and bake
  1. Layer half the sliced Yukon Gold potatoes in the bottom of the prepared baking dish, overlapping slightly, then season lightly with salt and black pepper.
  2. Spread the sautéed onion and garlic over the potatoes, then layer the browned kielbasa evenly on top.
  3. Add the remaining potato slices in a second layer on top.
  4. Pour the cheese sauce evenly over the casserole and spread with a spatula so it seeps into the layers.
  5. Sprinkle the reserved ½ cup sharp cheddar cheese over the top.
  6. Cover tightly with aluminum foil and bake for 45 minutes.
  7. Remove the foil and bake an additional 20–25 minutes until the top is golden and bubbly and the potatoes are completely tender when pierced with a fork.
Rest and serve
  1. Let the casserole rest for 10 minutes before serving.
  2. Garnish with chopped fresh chives or parsley and serve hot directly from the dish.

Notes

For the smoothest sauce, whisk the milk in slowly and keep the heat at medium while thickening so it coats the spoon without turning grainy. Refrigerate leftovers in an airtight container for up to 3 days; reheat covered at 350°F (175°C) until hot. Freeze yes (up to 2 months), but expect the texture to soften slightly. For a lighter version, use low-fat milk and reduced-fat cheddar; the bake will still layer and melt well.