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Heat oven to 350 degrees F. Coat a 13″ x 9″ baking dish with nonstick cooking spray.
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Bring a large pot of water to a boil. Cook pasta according to package directions, and then drain.
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Meanwhile, in a medium-sized saucepan, cook bacon over medium heat until crisp. Transfer to paper towels. Carefully pour off drippings, reserving 2 tablespoons in the pan. Add butter.
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Whisk flour into bacon grease until smooth. While whisking, slowly stream milk into flour mixture; whisk to remove any lumps. Stir in onion powder, salt,and pepper. Bring to a boil over medium-high heat,then reduce heat and simmer 2 minutes. In a large bowl, toss together cheddar, jack, and Farmer’s cheese.
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Remove milk mixture from heat; whisk in American cheese and 1 1/4 cups of the cheddar mixture. Toss bacon pieces with remaining shredded cheese.
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In pasta pot, combine cooked pasta and cheese sauce. Pour half into prepared dish. Sprinkle with half the bacon-cheese mixture. Repeat layering.
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Bake for 20 minutes. Increase oven temperature to broil and broil for 3 minutes, until the top is browned. Cool slightly before serving.