This Cheesy Potatoes with Smoked Sausage has been a go-to in my kitchen for quick weeknight dinners and potluck contributions. I first landed on this combination on a chilly weekend when my pantry offered russet potatoes and a package of smoked sausage, and I wanted something simple, satisfying, and crowd-friendly. It quickly earned a reputation around my table: the potatoes are tender but still hold their shape, the sausage adds that smoky, savory backbone, and the two cheeses—Velveeta for silky melting and sharp cheddar for tang—create a saucy blanket that crisps slightly at the edges. It's pure comfort food that doubles as a side or a filling main.

I love how forgiving this dish is. The timing is generous and the techniques are straightforward: parboil the potatoes so they finish perfectly in the oven, brown the sausage for flavor, build a quick roux-based sauce with butter and flour, then melt in the cheeses until glossy. It feeds a crowd—this version makes nine servings—and reheats beautifully. Family members always ask for the corners first because those bits are slightly golden and crunchy, while the center stays luxuriously creamy.

Ingredients

• Russet potatoes: Use about 4 cups diced, peeled russets (roughly 2 to 3 medium potatoes). Russets hold shape while becoming fluffy; choose firm potatoes without sprouts for best texture.
• Olive oil: 1 teaspoon to brown the sausage—extra-virgin works fine, but a neutral oil will brown more evenly if you prefer.
• Smoked sausage: 1 (14-ounce) package, sliced about 1/4 inch thick. Kielbasa or smoked kielbasa-style links bring the classic smoky flavor—look for brands you like for snacking.
• Unsalted butter: 4 tablespoons to form the roux; salted butter is okay if you reduce added salt later.
• All-purpose flour: 1/4 cup to thicken the sauce—measure lightly and whisk well to avoid lumps.
• Half-and-half or milk: 2 cups. Half-and-half yields a richer sauce; whole milk is a lighter, still-creamy alternative.
• Garlic powder: 1/4 teaspoon for background flavor; add a pinch of onion powder if you like more depth.
• Velveeta cheese: 8 ounces, cubed. This processed cheese melts smoothly and makes the sauce glossy; if unavailable, use an equal amount of processed melting cheese.
• Sharp cheddar cheese: 1 cup shredded, divided. Adds tang and a slight bite—freshly shredded melts better than pre-shredded blends.
• Salt and black pepper: To taste—start conservatively and adjust after the sauce comes together.
• Nonstick spray or butter: To grease a 9-inch square baking dish so the casserole releases easily.

Instructions

Prepare the baking dish and potatoes: Lightly grease a 9-inch square baking dish with nonstick spray or a thin smear of butter. Dice and peel russet potatoes so the pieces are roughly 1/2-inch to 3/4-inch—small enough to cook evenly. Place them in a pot of cold, salted water and bring to a gentle boil; simmer until just tender when pierced with a fork (about 8 to 10 minutes). You want them slightly undercooked so they hold their shape during baking. Drain and assemble the base: Thoroughly drain the parboiled potatoes and let steam briefly in the colander to remove excess moisture. Transfer the potatoes into the prepared baking dish so they are spread in an even layer, leaving space for the sausage. Brown the smoked sausage: Heat a large nonstick skillet over medium-high heat and add 1 teaspoon olive oil. Add the sliced smoked sausage in a single layer and cook until both sides develop a golden brown sear, about 3 to 4 minutes per side depending on thickness. Browning adds caramelized flavor and renders some fat—transfer the sausage to the baking dish, distributing it evenly among the potatoes. Make the cheese sauce (roux method): Wipe the skillet clean, then melt 4 tablespoons unsalted butter over medium heat. Add 1/4 cup all-purpose flour and whisk constantly for 1 minute to cook the raw flour taste. Slowly pour in 2 cups half-and-half while whisking to create a smooth sauce. Bring the mixture to a gentle simmer, reduce heat to low, and whisk in 1/4 teaspoon garlic powder. Finish the sauce with cheeses: With the heat low, add 8 ounces cubed Velveeta to the sauce in small batches, stirring until fully melted and glossy. Stir in half (about 1/2 cup) of the shredded sharp cheddar until incorporated; remove from heat and taste for seasoning. Add salt and freshly cracked black pepper to your preference—remember the sausage and Velveeta add saltiness, so start light. Combine and bake: Pour the cheese sauce evenly over the potatoes and sausage in the baking dish, ensuring all pieces are coated. Sprinkle the remaining 1/2 cup of shredded sharp cheddar on top for a browned finish. Bake in a preheated 350°F oven for 25 to 30 minutes until the top is bubbly and the edges turn golden. Rest and serve: Let the casserole rest for 5 minutes before scooping—this helps the sauce thicken slightly and makes serving neater. Serve warm with garnishes like chopped fresh parsley or chives if desired.

Storage Tips

Store cooled leftovers in an airtight container in the refrigerator for up to 4 days. For longer storage, transfer to a freezer-safe dish, wrap tightly in plastic wrap and foil, and freeze for up to 3 months. To reheat, thaw overnight in the refrigerator if frozen, then warm in a 350°F oven covered with foil for about 20 minutes; remove foil for the last 5 minutes to allow the top to bubble. Microwaving is fine for single portions—heat in 1-minute intervals and stir gently to distribute heat and sauce.

Ingredient Substitutions

If you prefer a lighter version, swap half-and-half for whole milk and reduce the amount of Velveeta to 4 ounces, adding 4 ounces extra-sharp cheddar for flavor. For a gluten-free version, use 1/4 cup cornstarch whisked into 1/4 cup cold milk before adding to the hot butter instead of flour, or use a gluten-free all-purpose flour. Swap smoked sausage with diced ham, cooked chicken, or a plant-based smoked sausage for a different protein profile—adjust seasoning because replacements vary in saltiness.

Serving Suggestions

This dish pairs beautifully with a crisp green salad dressed in a bright vinaigrette to cut through the richness. For a heartier meal, serve with steamed green beans or roasted Brussels sprouts. Garnish with chopped parsley or sliced green onions for color and a fresh bite. Calendar-friendly serving ideas include potluck style in buffet pans or plated alongside roasted vegetables for a Sunday supper.

Cultural Background

The idea of combining potatoes, smoky sausages, and melting cheeses has roots in American comfort-cooking traditions and midwestern casserole culture. One-pan, hearty dishes were popularized for family meals and church potlucks, where ease and volume mattered. The use of Velveeta reflects mid-20th-century American convenience trends: processed cheese offered consistent melt and texture that home cooks came to rely upon for creamy casseroles and dips.

Meal Prep Tips

To streamline weeknight prep, parboil and dice the potatoes a day ahead and keep them refrigerated in an airtight container. Brown the sausage and keep it separate; assemble the casserole the next day and refrigerate until ready to bake. Alternatively, fully assemble, cover, and refrigerate for up to 24 hours—add about 10 to 15 minutes to the bake time if straight from the fridge. Use oven-safe labels to mark dates for easy rotation.

This dish is a reliable, beloved comfort meal that rewards simple technique with cozy flavor. Whether you bake it for a family dinner, bring it to a potluck, or prepare it for make-ahead weekday meals, it’s one of those reliable, crowd-pleasing dishes that becomes part of your regular rotation. Enjoy the warm, cheesy comfort—and don’t forget to fight for that crispy corner!