Smoked Shotgun Shells Bacon

Bacon has earned its place as the must-have appetizer at my gatherings. Each crispy bacon-wrapped manicotti shell holds a creamy and spicy filling packed with ground beef, Italian sausage, sharp cheddar, onions, and jalapenos. The entire bundle is brushed with barbecue sauce then smoked until golden and melty. The result is a dish that looks like a professional pitmaster made it but only takes a few easy steps. These are my favorite when I need one hearty dish to please a hungry crowd at barbecue parties or game days.

I first made these while experimenting for a backyard smoker competition. My cousin’s jaw dropped at first bite and that started the tradition—now my family texts me requests for shotgun shells at every family event.

Ingredients

• Two 8 ounce boxes manicotti shells: Choose a sturdy pasta that will not shatter when stuffed
• One and a half pounds ground beef: Eighty percent lean gives juicy and flavorful meat
• One pound hot Italian sausage: Look for links with good seasoning that hold their shape well
• One medium onion diced: Sweet onions wonderful for balancing spice and flavor
• Two cups sharp cheddar cheese: Pick a quality block and shred it fresh for melting
• Six ounces cream cheese: Softened cream cheese will blend smoothly and keep everything creamy
• One jalapeno finely diced: Remove seeds for less heat or keep them in for more punch
• Two teaspoons Cajun style seasoning: My go-to is Slap Ya Mama or any favorite Cajun blend
• Two teaspoons garlic powder: Powdered garlic prevents burning during smoking and mixes smoothly
• Two teaspoons black pepper: Freshly ground adds a deeper kick
• One teaspoon red pepper flakes: Go for more or less spice based on your crowd
• One third cup barbecue sauce: Use a good thick barbecue sauce that adds sweetness and will not water down the filling
• Two sixteen ounce packages bacon: Some thicker cuts work best but have extra ready in case of breakage
• Extra barbecue sauce for basting: My favorite is a sweet variety for glossy caramelized bacon

Instructions

Prepare the Smoker:

Set your smoker to heat to two hundred fifty degrees Fahrenheit with hickory or apple wood. The lower heat allows the pasta to soften and the bacon to crisp without burning.

Mix the Filling:

Combine ground beef, sausage, cheddar, cream cheese, onion, jalapeno, seasoning, garlic powder, pepper, red pepper flakes, and one third cup of barbecue sauce in a large bowl. Use your hands to gently blend until just combined to keep the texture light.

Stuff the Manicotti:

With dry hands, hold each uncooked manicotti shell upright and stuff from both ends with the meat mixture. Press gently using a small spoon or your fingers. Fill completely but do not pack too tightly or the pasta may crack.

Wrap with Bacon:

Lay out each stuffed shell and wrap with bacon. Begin at one end and overlap the strips slightly at the center so the seams stay closed. If a shell is long or feels loose, wrap a second slice to seal the filling. Secure with toothpicks soaked in water so they do not catch fire.

Glaze with Sauce:

Brush each bacon-wrapped shell on all sides with extra barbecue sauce. This will give the bacon its caramelized sugar crust. Set shells on a wire rack over a rimmed baking sheet for easy transfer to your smoker.

Smoke Slow and Steady:

Arrange shells in the preheated smoker. Cook for one hour, then flip each piece gently and brush again with more sauce. Smoke for one more hour until bacon is crisp and the internal temperature hits one hundred sixty degrees.

Cream cheese is my secret for a silky filling It helps bind the meat and cheese together so each bite stays creamy. My favorite memory is making these side by side with my dad before a tailgate. He insisted on extra barbecue sauce and now I always make a double batch just for him.

Storage Tips

Keep leftovers in an airtight container in the refrigerator for up to four days. Reheat in the oven at three hundred fifty degrees for about ten to fifteen minutes. Microwaving is faster but can make the bacon soft so use a wire rack when possible to crisp them back up. You can also freeze assembled but uncooked shells for up to two months then smoke straight from the freezer just add twenty minutes to the cooking time.

Ingredient Substitutions

Use ground turkey for a lighter version and add a little olive oil or extra barbecue sauce to avoid dryness. Mild sausage or bell pepper is the fix if your crowd cannot handle spicy jalapeno. Any semi-firm cheese like mozzarella or Monterey Jack melts well and gives a fun flavor twist.

Serving Suggestions

Set out these bacon-wrapped shells next to small bowls of ranch or extra barbecue sauce for dipping. I love pairing them on a big rustic cutting board with pickled veggies. For a full meal, serve alongside classic BBQ sides like coleslaw or baked beans. Cut each piece in half on a sharp diagonal for nifty bite-size party snacks.

Cultural and Smoking Context

Shotgun shells are a modern Southern barbecue innovation named for their tubular pasta shape similar to shotgun ammunition. The trend has caught on at cookoffs and backyard gatherings for good reason—they deliver smoky hearty flavor in every bite. Smoking transforms both the bacon and the pasta for a texture you will not find any other way.

Seasonal Adaptations

Try swapping in diced roasted red pepper or sun-dried tomato for summer flavor. Mix in chopped fresh herbs like parsley or chives during spring for color. Add a pinch of ground cumin or smoked paprika to the filling for fall warmth.

Success Stories

The first time I took these to a potluck the platter emptied in seconds. I even had a guest ask me for the recipe before dessert was served. Since then I have made shotgun shells for everything from backyard birthdays to holiday feasts and every time they are the first snack to go.

Freezer Meal Conversion

Assemble the shells fully and wrap tightly in plastic wrap then foil. Freeze for up to two months. When you are ready to cook place frozen shells on your smoker and add about twenty extra minutes to the total cook time.

With just a little patience and the right wood smoke you will create the kind of unforgettable appetizer that disappears long before you get to sit down. Bacon shotgun shells are the showstopper on any table and one of those recipes you will turn to again and again.

Common Questions About the Recipe

→ Do I need to cook the meat before stuffing the shells?

No, use raw ground beef and sausage. Smoking will cook the filling thoroughly inside the shells.

→ Can these be prepared in advance?

Yes, assemble ahead and refrigerate. Apply barbecue sauce just before smoking for best flavor.

→ What cheese varieties work inside the shells?

Sharp cheddar, mozzarella, or pepper jack melt beautifully. Experiment to suit your taste.

→ How can I prevent manicotti shells from breaking?

Stuff gently from both ends, avoid overfilling, and use quality shells to minimize cracks.

→ What’s the best way to reheat leftovers?

Reheat in a 350°F oven on a wire rack for 10–15 minutes to restore crispiness and flavor.

→ Can I substitute ingredients for a milder or lighter version?

Swap ground turkey for beef, mild sausage or bell pepper for heat, and mozzarella for cheddar.