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Bite into these smoked shotgun shells and you'll see why they're the talk of every barbecue. You’ve got hot Italian sausage and beef mixed with cheddar, jalapeno, cream cheese, onions, bold spices, all stuffed inside manicotti tubes. Each one’s wrapped up in bacon, coated in barbecue sauce, and smoked till everything melts and the bacon gets crisp. The first time I brought these out on game day, people couldn’t believe they started with plain, uncooked pasta tubes.
After I brought these to my own backyard grill night, everyone made me the official shotgun shell supplier. The creamy filling and smoky bacon on the outside makes them totally impossible to pass up.
Tasty Ingredients
- Bacon: Thick-sliced holds up best Try not to use thin cut so it wraps well
- Extra barbecue sauce: For basting at the end Any store-bought or homemade you like will do
- Barbecue sauce: Adds that sticky finish Choose one with a smoky edge for best taste
- Red pepper flakes: Gives a little jolt If you want less heat just sprinkle lightly
- Black pepper: Coarse grind punches up flavor Works best for tiny bursts of heat
- Garlic powder: Easy way to add deep flavor Go with dried here, not fresh
- Slap Ya Mama seasoning: Adds that Cajun pop Try to find one with real quality spices
- Jalapeno: Toss in seeds for more spice or leave them out for less
- Medium onion: Dice small for even flavor Sweetness balances the heat
- Cream cheese: Let it warm up first Makes mixing a breeze
- Sharp cheddar cheese: Shred your own for super melt Buy a block, skip the bag
- Hot Italian sausage: Brings heat and depth Remove the casing from fresh links
- Ground beef: Meaty bite and richness 80% lean is just right
- Manicotti shells: Pick the sturdiest tubes you can Find ones that aren’t cracked
Easy Step Guide
- Let Them Rest:
- Give the shells about five minutes to cool and set when they’re done That way the cheese stays put and bacon crisps even more
- Smoke Them Up:
- Lay shells straight on your smoker grates or keep them on a sheet Tray helps catch sauce drips Smoke for an hour flip and give them more sauce Then smoke another hour till the bacon looks deep brown and pasta turns soft
- Add More Sauce:
- Brush a big swipe of your favorite barbecue sauce over each bacon wrapped shell Set them up on a sheet pan to catch all that sauce
- Wrap in Bacon:
- Take a shell and gently coil a bacon slice from one end to the other You may need two slices Tips: Cover all open ends and tuck any loose edges under for neatness
- Get Shells Filled:
- Push the cheese and meat mix into both ends of each dry manicotti shell Don’t pack it super tight—just fill up, leaving no gaps Use your pinky or spoon handle for stubborn spots
- Mix Up Filling:
- Dump everything in a big bowl—the beef, sausage, cheddar, onion, spicy bits, cream cheese, and seasonings plus a splash of barbecue sauce Really squeeze it all together till it’s blended, but stop if it gets sticky
- Heat the Smoker:
- Fire your smoker to 250 (indirect) This low heat slowly crisps the bacon while pasta softens inside
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My favorite part’s when the bacon goes super crispy and mixes with all that melty filling inside. Every time I’ve made a double batch, folks clean the platter before I even get one. Everyone in my family wants extra barbecue for dipping—those sticky sweet outside edges always disappear first!
Leftover Help
Slide any leftovers into a sealed container and chill for up to four days Slice up the shells before stashing them so they warm up quick later Pop them on a rack in a 350 oven till heated through and bacon crisps up again Got extras? Freeze for a month, then reheat when cravings hit
Swaps and Options
Not a fan of heat? Sweet Italian sausage works instead of hot Barbecue sauce is all about taste – pick a smoky one if you like Jalapenos can swap for mild poblanos or bell peppers, and turkey bacon’s fine—just cook until it’s fully crisp
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Serving Ideas
Lay them out on a big tray and scatter green onions or minced jalapeno on top Don’t forget bowls of barbecue or ranch for dipping Mini buns turn these into little sandwiches for parties or tailgates too
Story Behind It
Shotgun shells are newer favorites on the American barbecue scene, dreamed up by DIY pitmasters. It’s like stuffed pasta meets smoky sausage, cooked until bacon turns crunchy. They’re always the first thing to disappear from the snack table!
Common Recipe Questions
- → Which pasta holds up best when filled?
Go for manicotti shells. They’re thicker and bigger, so they won’t fall apart and they can handle all the tasty filling.
- → Can you skip browning the meat before stuffing?
Totally fine to stuff it raw. All the meat will cook inside the pasta while it smokes, so it stays nice and juicy.
- → How do you keep manicotti from breaking while stuffing?
Work gently from both sides and don’t force it in. If your filling’s a little chilled, it slides in easier too.
- → Is the heat level easy to change?
Absolutely, just leave out the jalapenos for mild or toss in extra if you want more kick—change up the spices too.
- → Which wood chips do you use for smoky flavor?
Hickory or applewood both give it a nice smoke, but honestly, whatever wood chips you like will taste great.
- → How should you warm up leftovers without ruining the crunch?
Pop 'em in a 350°F oven until they're hot again. That way, the bacon stays crispy instead of rubbery.