Smoked Shotgun Shells Recipe

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A Smoky, Bacon-Wrapped BBQ Favorite Everyone Will Love

Few things stir up excitement at a backyard barbecue like a tray full of Smoked Shotgun Shells. These meat-stuffed pasta tubes, lovingly wrapped in bacon and glazed with barbecue sauce, are juicy, smoky, savory, and absolutely bursting with flavor. It’s a unique combination of textures—crispy bacon on the outside, tender pasta, gooey cheese, and a hearty meat center that’s been kissed by wood smoke.

Though the name might be intimidating, Smoked Shotgun Shells are surprisingly easy to prepare and are one of the most satisfying smoker recipes out there. Whether you’re hosting a game day, summer cookout, or just want to impress friends and family with something new, this dish delivers bold flavor and smoky richness in every bite.

What Are Smoked Shotgun Shells?

Smoked Shotgun Shells get their name because the pasta shells (typically manicotti) look like shotgun shells once they’re stuffed and wrapped. The shells are filled with a seasoned meat-and-cheese mixture, then wrapped in bacon, brushed with barbecue sauce, and slow-cooked in a smoker until the bacon is crisp, the pasta is tender, and the flavors are perfectly melded.

The beauty of this recipe is in its flexibility—different meats, cheese blends, sauces, and even seasonings can be used to make it your own. Best of all, no need to pre-boil the pasta. The moisture from the meat and bacon cooks the shells perfectly during smoking.

Ingredients

For the Shells (Makes ~28 Shotgun Shells)

  • 2 boxes (8 oz each) manicotti pasta shells (uncooked)

  • 1½ lbs ground beef

  • 1 lb hot Italian sausage

  • 1 medium onion, finely chopped

  • 6 oz cream cheese, softened

  • 2 cups shredded sharp cheddar cheese

  • 1 jalapeño, finely diced (optional for heat)

  • 2 tsp garlic powder

  • 2 tsp black pepper

  • 1 tsp crushed red pepper flakes

  • 2 tsp Slap Ya Mama seasoning (or your favorite all-purpose BBQ rub)

  • â…“ cup barbecue sauce (plus more for basting)

  • 2 packages thick-cut bacon (about 24 oz total)

Optional Add-ins:

  • ½ tsp smoked paprika

  • ¼ cup chopped green onions

  • ½ tsp liquid smoke for added depth

  • 1 tbsp Worcestershire sauce

Tools You’ll Need

  • Smoker or grill with wood chips (hickory, applewood, or mesquite)

  • Large mixing bowl

  • Spoon or piping bag for stuffing shells

  • Basting brush

  • Baking sheet with a wire rack

  • Foil or parchment paper

  • Meat thermometer (optional but recommended)

How to Make Smoked Shotgun Shells

Step 1: Prepare the Smoker

Start by preheating your smoker to 250°F (121°C). Choose a mild to medium wood like hickory, apple, or cherry for a smoky but not overwhelming flavor.

If using a pellet smoker, make sure your hopper is full to avoid refueling during the cook.

Step 2: Make the Meat Filling

In a large mixing bowl:

  1. Combine ground beef and hot Italian sausage.

  2. Add the cream cheese, shredded cheddar, diced onion, and jalapeño.

  3. Mix in the garlic powder, black pepper, red pepper flakes, seasoning blend, and barbecue sauce.

  4. Use your hands or a sturdy spoon to mix until everything is thoroughly combined.

Pro Tip: Refrigerating the filling for 20 minutes can make it easier to stuff into the shells.

Step 3: Stuff the Pasta Shells

Use a spoon, piping bag, or your hands to carefully fill each uncooked manicotti shell. Try to avoid air pockets by stuffing from both ends.

Helpful Tip: If you’re having trouble filling the shells, snip the corner off a zip-top bag and pipe the filling in. Press gently to avoid cracking the pasta.

Step 4: Wrap in Bacon

Once filled, wrap each manicotti shell completely in bacon. This usually takes 1 to 1½ slices of bacon per shell, depending on the size and your wrapping style.

Wrap tightly so that the bacon seals the ends. This helps retain moisture and ensures even cooking.

Place wrapped shells on a baking sheet or directly on a wire rack.

Step 5: Apply the Barbecue Sauce

Brush each bacon-wrapped shell generously with your favorite barbecue sauce.

Sauce Suggestions:

  • Classic Kansas City-style BBQ sauce for sweetness

  • Spicy chipotle sauce for heat

  • Honey bourbon BBQ for complexity

Step 6: Smoke Low and Slow

Place your bacon-wrapped shells directly on the smoker rack or a raised wire rack over a baking sheet.

Smoke at 250°F for 2 hours total:

  • First hour: Let them smoke undisturbed to build up flavor and render the bacon.

  • Second hour: Flip each shell, brush again with barbecue sauce, and smoke until bacon is crispy and the internal temp hits around 165°F–175°F.

Note: You can go longer if you want a more intense smoky flavor. Just watch the bacon to avoid burning.

How to Tell When They’re Done

  • The bacon should be crisp and fully rendered.

  • The shells should be tender but still holding their shape.

  • The internal temperature should be at least 165°F to ensure the meat is fully cooked.

  • The filling should be gooey, juicy, and slightly caramelized from the sauce.

Serving Suggestions

Serve Smoked Shotgun Shells hot off the smoker, sliced in half, or whole. They’re hearty enough to be a main dish, but also work great as appetizers.

Great Pairings:

  • Creamy coleslaw

  • Loaded baked potatoes

  • Macaroni & cheese

  • Cornbread

  • Pickles or pickled onions

  • Ice-cold beer or sweet iced tea

Flavor Variations

1. Tex-Mex Shotgun Shells

Add taco seasoning, black beans, and pepper jack cheese to the filling. Top with fresh cilantro and avocado cream.

2. Breakfast Shotgun Shells

Use breakfast sausage, scrambled eggs, cheddar, and chives. Serve with maple syrup or hot sauce.

3. Spicy Buffalo Shells

Use shredded chicken, cream cheese, hot sauce, and blue cheese. Wrap in bacon and glaze with a mix of hot sauce and butter.

4. Sweet Heat BBQ

Use maple bacon, mild sausage, and a glaze made of BBQ sauce mixed with apricot jam or brown sugar.

5. Cheeseburger Style

Add diced pickles, mustard, and ketchup to the meat mix. Use American cheese and serve with extra burger sauce on the side.

Tips for Success

  • Do Not Boil the Pasta: The pasta will cook in the smoker from the moisture in the meat and bacon. If you’re nervous, parboil for just 1 minute.

  • Wrap Tightly: Make sure bacon covers the shell ends to prevent drying out.

  • Use a Rack: Elevates the shells and ensures even smoke circulation.

  • Let Them Rest: Like brisket, resting for 5–10 minutes helps juices redistribute.

Make-Ahead and Storage

Make-Ahead:

  • Assemble the shells and refrigerate for up to 2 days before smoking.

  • This helps soften the pasta and intensifies the flavor.

  • Great for prepping ahead of events or holidays.

Refrigerate:

  • Store leftovers in an airtight container for up to 4 days.

Freeze:

  • Cool completely, then freeze in a single layer. Transfer to a freezer bag or container for up to 3 months.

Reheat:

  • Bake at 350°F, covered with foil, for 15–20 minutes.

  • Uncover and bake for 5–10 minutes to re-crisp the bacon.

Cooking Without a Smoker

If you don’t have a smoker, don’t worry. You can still make delicious Shotgun Shells:

Oven Method:

  • Preheat oven to 300°F.

  • Bake on a wire rack over a baking sheet.

  • Bake covered with foil for 1 hour, then uncover and bake another 30 minutes to crisp the bacon.

Air Fryer:

  • Preheat to 375°F.

  • Air fry 2–4 at a time for 15–20 minutes, turning halfway through.

Frequently Asked Questions

Can I make these vegetarian?
Yes! Use plant-based sausage, vegan cream cheese, and dairy-free cheese. Use vegan bacon or skip it and brush with BBQ sauce before baking.

Can I add rice or grains to the filling?
Not recommended. The pasta needs moisture from the meat mixture to cook properly.

Can I use other pasta shapes?
Manicotti works best, but you can also try cannelloni. Avoid pasta shells that are too thin or small.

What if my bacon isn’t crisp enough?
Broil the shells for 2–3 minutes at the end of cooking, or air fry briefly for extra crisp.

Final Thoughts

Smoked Shotgun Shells are the ultimate mashup of comfort food and barbecue excellence. They’re tender, smoky, meaty, cheesy, and wrapped in crispy bacon—a combination that’s nearly impossible to resist.

Perfect for tailgates, family gatherings, or just leveling up your smoker game, they’re bound to become your new favorite smoked appetizer or main course. With tons of room for customization and guaranteed flavor payoff, there’s no reason not to give this epic dish a try.

Whether you’re smoking them low and slow or baking them in the oven, Shotgun Shells are a recipe you’ll come back to again and again.

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