Smoked Shotgun Shells Bacon Shells

Smoked Shotgun Shells are an appetizer that turns every backyard gathering into a buzz of excitement. Mixing seasoned beef and sausage with plenty of cheese and aromatics then stuffing it all in manicotti and wrapping each piece in bacon before a long slow smoke creates an irresistible bite. Every piece is juicy inside and crackly outside with that sweet tangy barbecue glaze. This is the kind of recipe people talk about after the party.

My family cleared the plate the first time I made these. Now they are a must for every game day or cookout and people always ask for the recipe.

Ingredients

• Manicotti shells: These sturdy tubes hold the filling perfectly and get tender while smoking. Look for ones without any cracks
• Ground beef: Adds richness and meaty flavor. Use freshly ground beef with good marbling for juicy filling
• Hot Italian sausage: Brings bold flavor and a little spice. Buy from the butcher counter for freshest taste
• Sharp cheddar cheese: Melts for gooey pockets in the filling. Freshly shredded cheese will melt better than pre-shredded bags
• Cream cheese: Gives creaminess and helps hold everything together. Let it come to room temperature first for easier mixing
• Onion: Adds a little sweetness and depth. Finely dice for best texture
• Jalapeno: Gives subtle heat and a fresh bite. Remove seeds if you prefer milder flavor
• Slap Ya Mama seasoning: Brings a Cajun kick. Any seasoned salt blend works if you cannot find this
• Garlic powder: Lends savory depth that complements the meats
• Black pepper and red pepper flakes: Build layered spiciness. Adjust both to your preferred flavor
• BBQ sauce: Sweetness and tangy notes tie everything together. Use your favorite brand and make sure it is thick enough to stick to the shells
• Bacon: Wraps the whole package delivering smoky crispness. Thick sliced bacon gives best texture

Step-by-Step Instructions

Prep the smoker:

Set your smoker to 250 degrees. Let it come to temp while you prepare the shells for the best smoke flavor

Mix the filling:

In a large bowl combine ground beef hot sausage cheddar cheese cream cheese diced onion diced jalapeno barbecue sauce and all seasonings. Use clean hands or a sturdy spoon to distribute everything evenly. Make sure cream cheese is fully worked in for smooth texture

Stuff the shells:

Take uncooked manicotti shells. Gently fill from both ends with the meat mixture pressing lightly but not so hard you break the shells. Fill all the way to the ends with no air pockets for best shape and baking

Wrap with bacon:

Lay a slice of bacon on a board. Roll a filled shell up tightly so the bacon covers all sides and overlaps at the ends. Use a second piece if needed so there are no gaps. Place on a tray with the seam side down

Add the first barbecue glaze:

Using a brush coat both sides of each bacon-wrapped shell with barbecue sauce for a sticky flavorful layer that caramelizes in the smoker

Smoke low and slow:

Arrange shells directly on smoker grates or a wire rack over a sheet pan. Smoke for one hour then turn the shells over. Brush more barbecue sauce on all sides and continue smoking for another hour or so until bacon is dark crispy and filling is cooked through

Rest and serve:

Remove shells from the smoker using tongs. Let them rest a few minutes so the juices settle before serving hot

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The bacon is my favorite part because it crisps up perfectly and adds such a smoky punch to each bite. I remember my uncle teaching me the trick of flipping halfway through to get that even color and caramelization all around the shell. It is simple but makes a huge difference.

Storage Tips

Allow any leftovers to cool completely before storing. Arrange in an airtight container with parchment or wax paper between layers to prevent sticking. They keep well in the fridge for up to three days. Reheat in a 300 degree oven to restore some crispness or toss them back on the smoker for a short time to refresh the texture.

Ingredient Substitutions

If you cannot find hot Italian sausage use sweet Italian and add extra red pepper flakes for heat. For the manicotti shells jumbo rigatoni can be used instead. Monterey Jack or mozzarella work as milder cheese swaps for cheddar. Regular seasoned salt can sub in for Slap Ya Mama if needed. Turkey bacon works if you want a lighter option but may not get quite as crisp.

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Serving Suggestions

Slice each shell into halves or thirds for simple party bites or serve whole with extra barbecue sauce for dipping. These pair beautifully with tangy pickles fresh slaw or even a zippy ranch dip. My family likes them alongside grilled corn and baked beans for a true cookout feast.

The Story of Smoked Shotgun Shells

This recipe is a creative twist on classic barbecue stuffed peppers and Italian stuffed pasta. The shell keeps the filling so juicy while the smoked bacon brings electric flavor. Smoked Shotgun Shells have become a favorite at tailgates and backyard gatherings all across the South thanks to their bold taste and easy finger food format.

Recipe FAQs

→ Can I use other types of sausage?

Yes, try mild Italian or breakfast sausage for a different flavor, or use any sausage you prefer to customize the heat level.

→ Should the meat be cooked before stuffing the shells?

No, the ground beef and sausage go into the shells raw. They cook completely during the smoking process.

→ What kind of wood chips are best for smoking?

Hickory and applewood are great choices, lending a robust smoky flavor that pairs well with bacon and barbecue sauce.

→ Can I prepare the shells ahead of time?

Absolutely! Assemble the shells and refrigerate them a few hours in advance. Smoke them when ready to serve.

→ How do I know when the shells are ready?

The bacon should be crisp, the shells tender, and the filling hot throughout after about two hours of smoking.