Smoked Shotgun Shells take all the bold flavors of barbecue and wrap them up in a single irresistible bite. Picture gooey cheese-packed beef and sausage stuffed into pasta shells then wrapped in crispy bacon and slathered in barbecue sauce. This is the ultimate crowd-pleaser for game day or any backyard get-together.

Ingredients

• Manicotti shells: They hold up well during smoking and stay perfectly al dente Try to choose sturdy uncracked shells
• Ground beef: Adds hearty flavor and moisture Look for 80 20 for best juiciness
• Hot Italian sausage: Packs in spice and more depth Use fresh bulk sausage that is not overly lean
• Sharp cheddar cheese: Melts beautifully and gives great tang I always grate my own for meltiness
• Cream cheese: Brings extra creaminess and helps bind the filling Choose block-style full fat for smoothest results
• Onion: Finely diced for a subtle sweetness and texture Go for fresh firm onions
• Jalapeno: Adds a gentle heat Remove seeds for less spice or keep them for extra punch
• Slap Ya Mama seasoning: A zesty Cajun blend for the best kick If you cannot find it use a mix of cayenne garlic powder and black pepper
• Garlic powder: Balances and deepens flavor Use fresh and aromatic powder
• Black pepper: Essential background warmth Grind it fresh for best aroma
• Red pepper flakes: For those who love a hint of lingering heat Use fresher flakes for max impact
• Barbecue sauce: Gives sweet smoky glaze and moisture Try to pick a thick rich kind that you love as the flavor comes through boldly
• Bacon: The crispy wrap that finishes it all off Thick-cut holds up better and crisps well

Step-by-Step Instructions

Prep the Filling:

Thoroughly mix ground beef Italian sausage cheddar cream cheese onion jalapeno Slap Ya Mama seasoning garlic powder black pepper red pepper flakes and barbecue sauce in a large bowl Use your hands to combine until evenly distributed but do not overwork the mix so it stays tender

Stuff the Manicotti Shells:

Take uncooked manicotti shells and gently fill from each end with the meat mixture A small spoon or your fingers work best Stuff until fully packed but be gentle to avoid cracking the shells Filling from both ends helps eliminate air pockets and ensures complete coverage

Wrap in Bacon:

Cut bacon strips as needed Wrap each filled shell entirely covering the ends If you like crispier results use a single layer of thick bacon but for even more flavor and coverage use two slices slightly overlapping

Baste with Barbecue Sauce:

Lightly brush barbecue sauce over both sides of each wrapped shell Set shells on a baking sheet to rest while you finish preparing the rest This base coat caramelizes on the smoker later

Smoke the Shells:

Arrange shells in your preheated smoker at 250 degrees Place directly on clean racks or over a foil-lined tray Smoke for 60 minutes then flip each shell Brush with additional barbecue sauce for extra flavor and shine Continue smoking for another 60 minutes or more until the bacon gets golden brown and crisp atop smoky pasta and bubbling cheese

Serve and Enjoy:

Remove the shells from the smoker They are best served hot right off the grill with an extra drizzle of barbecue sauce

Save

The creamy sharpness from cheddar and cream cheese is always the highlight for me It melts through the filling so perfectly that every bite feels special One time my son helped me wrap the shells and got barbecue sauce everywhere but it was his favorite part it made the kitchen feel even more festive

Storage Tips

Let the smoked shells cool completely before wrapping them tightly in foil or storing them in an airtight container They keep in the fridge for up to four days and reheat best in a hot oven to re-crisp the bacon If you want them for later the uncooked stuffed and wrapped shells can be frozen then thawed and smoked straight from the fridge

Ingredient Substitutions

You can swap ground turkey or chicken for beef if you want something lighter For extra heat try adding chopped chipotle peppers or extra jalapenos Instead of sharp cheddar you can go with pepper jack or gouda for a different twist If you do not have manicotti shells try cannelloni but avoid more fragile pasta shapes that might break

Serving Suggestions

These are hearty enough for the main event at a BBQ but also amazing as appetizers alongside pickles slaw or chips They pair especially well with tangy salads or any bright crunchy side Serve with extra barbecue sauce on the side for dipping I like setting out toothpicks for easy grabbing at parties

Save

Cultural Context

Smoked Shotgun Shells got their name for looking a bit like real shotgun shells once wrapped and smoked With roots in Southern barbecue culture they show how home cooks love reimagining comfort food by blending pasta cheesy filling and smoky grilling all in one These have become a backyard BBQ favorite and always spark conversation

Recipe FAQs

→ Can I use a different type of pasta shell?

Manicotti works best for stuffing, but large cannelloni can also be used if manicotti isn’t available.

→ Should I pre-cook the manicotti shells?

No, the shells are stuffed uncooked. Smoking with the moist filling cooks the pasta thoroughly.

→ Which wood chips are best for smoking?

Hickory or applewood chips add a nice balance of smoke and sweetness for these shells.

→ Can I make these in advance?

Yes, the shells can be assembled and refrigerated for several hours before smoking.

→ What’s the ideal internal temperature?

The filling should reach 165°F for safe consumption and best texture.

→ Is it possible to make them less spicy?

Reduce or omit the jalapeno and red pepper flakes for a milder flavor profile.