Heat your grill to 400°F, setting it up for direct grilling.
Cook the macaroni according to package directions. After draining, lightly coat the pasta with oil to prevent sticking. Set aside.
In a cast iron skillet, heat the diced green chiles over medium-high heat for about a minute. Pour in the heavy cream and bring to a simmer. Lower the heat to medium.
In a bowl, toss the grated cheddar with the cornstarch. Gradually whisk the cheese into the simmering cream, a handful at a time, allowing each batch to melt before adding more. Once smooth, tear up six slices of American cheese and stir them into the sauce. Mix the cheese sauce with the cooked macaroni, seasoning it with garlic and herb seasoning. Keep warm.
Cook the bacon until crispy, then set it aside.
Season the burger patties with garlic and herb seasoning. Grill the patties until they reach an internal temperature of 155°F. Add a slice of American cheese to each patty, grilling just long enough to melt the cheese. Remove the patties from the grill, cover with foil, and set aside.
Briefly toast the buns on the grill until they’re golden brown.
Assemble the burgers: Spread chipotle ketchup on the bottom half of each bun. Place the grilled patty on top, followed by two slices of bacon, a generous scoop of the mac 'n cheese, and the top bun. Enjoy your decadent creation!