Smoked Shotgun Shells

Get ready to meet the ultimate BBQ appetizer that turns heads and steals the show — smoked shotgun shells. These flavor bombs are made by stuffing manicotti pasta shells with a spicy, cheesy meat filling, wrapping them in bacon, and slow-smoking them until everything melds together into smoky, juicy perfection. Glazed with a sticky BBQ sauce and bursting with melty cheese, each bite is a savory, spicy, smoky dream that’s just begging to be devoured.

Behind the Recipe

The first time I heard of smoked shotgun shells, I thought it was a joke. Pasta and bacon on the smoker? But once I tried it, I was hooked. It combines everything I love — bold meat, gooey cheese, spicy jalapeños, smoky bacon, and sweet barbecue — into one epic handheld bite. Now, it’s my go-to whenever I fire up the smoker for a game day, backyard cookout, or just when I want to impress friends with something different.

Recipe Origin or Trivia

While smoked shotgun shells might sound like something straight out of a backyard legend, they’ve become a viral hit in BBQ circles. The name comes from the shape — stuffed manicotti shells that resemble shotgun shells — and the smoky cooking method. What started as a fun experiment has evolved into a must-have recipe for pitmasters and home grillers alike, proving that the combination of pasta, meat, and smoke was meant to be.

Why You’ll Love Smoked Shotgun Shells

Trust me, you’re going to love this. Here’s why:

Versatile: Great as an appetizer, main dish, or BBQ side.

Budget-Friendly: Makes a big batch with simple ingredients.

Quick and Easy: Prep in advance, then let the smoker do the work.

Customizable: Adjust the spice level, meat blend, or cheeses to your taste.

Crowd-Pleasing: Smoky, cheesy, bacon-wrapped pasta? Enough said.

Make-Ahead Friendly: Assemble ahead, refrigerate overnight, and smoke the next day.

Great for Leftovers: Reheat beautifully and still taste amazing.

Chef’s Pro Tips for Perfect Results

These little flavor bombs are simple to make, but a few pro tricks will elevate them:

1. Stuff the shells fully but not too tight: Leave room for the filling to expand as it cooks.
2. Wrap bacon tightly: Overlapping slightly helps it stay put and get crispy.
3. Let them rest before smoking: Refrigerating helps the pasta soften and the flavors meld.
4. Glaze near the end: BBQ sauce should go on in the final 15 minutes to avoid burning.
5. Use indirect heat: Smoking low and slow prevents the bacon from overcooking before the inside is done.

Kitchen Tools You’ll Need

You don’t need a full pitmaster setup — just a few essentials:

Smoker or Grill with Indirect Heat Setup: To get that signature smoky flavor.
Mixing Bowl: For blending the meat and cheese filling.
Small Spoon or Piping Bag: To stuff the manicotti shells.
Tongs: For placing and flipping the shells without piercing them.
Baking Sheet or Grill Tray: To transfer the shells in and out of the smoker easily.
Basting Brush: To glaze with BBQ sauce toward the end.

Ingredients in Smoked Shotgun Shells

This ingredient list is packed with flavor, spice, and smoky goodness. Here’s what you’ll need:

1. Ground Beef (90/10): 1 pound – Lean enough to avoid too much grease, but juicy for that perfect filling.
2. Chorizo: 1 pound – Spicy, flavorful, and adds bold depth to the meat blend.
3. Pepper Jack Cheese: 2 cups, shredded – Melty with a spicy kick that pairs perfectly with the meats.
4. Philadelphia Cream Cheese: ½ block (4 oz) – Adds creaminess and helps bind the filling.
5. Pickled Jalapeños: 1 cup, minced – Brings tang, heat, and a pop of flavor.
6. Manicotti Shells: 10, uncooked – The sturdy vessel that holds all that goodness and mimics the “shell.”
7. Bacon (Thin-Sliced): 1 package – Wraps each shell with smoky, salty perfection.
8. Traeger Garlic & Chili Pepper Rub: 3 tablespoons – Adds smoky, garlicky heat right on the outside.
9. Kinder’s Gold BBQ Sauce: ⅓ cup – A sweet, tangy glaze that caramelizes beautifully.

Ingredient Substitutions

Switch it up based on what’s in your kitchen:

Chorizo: Use Italian sausage, breakfast sausage, or all ground beef.
Pepper Jack Cheese: Try cheddar, Monterey Jack, or mozzarella.
Cream Cheese: Ricotta or mascarpone can work in a pinch.
Pickled Jalapeños: Use fresh jalapeños for extra heat or skip for mild.
Manicotti Shells: Jumbo pasta shells can be used, but handle with care.

Ingredient Spotlight

Manicotti Shells: These pasta tubes are strong enough to hold a hearty filling without breaking, and soften perfectly in the smoker when rested beforehand.

Chorizo: This spiced sausage takes the flavor profile up several notches, blending smoky paprika and garlic into every bite.

Instructions for Making Smoked Shotgun Shells

Let’s roll up our sleeves and get smoking. Here’s how to bring it all together:

1. Preheat Your Equipment:
   Heat your smoker to 250°F using indirect heat. Use a mild wood like hickory or apple for balanced smoke.
2. Combine Ingredients:
   In a large bowl, mix ground beef, chorizo, shredded pepper jack, cream cheese, and minced jalapeños until well combined.
3. Prepare Your Cooking Vessel:
   Stuff each uncooked manicotti shell with the meat mixture, filling to the edges but not overflowing.
4. Assemble the Dish:
   Wrap each shell tightly with a slice of bacon, slightly overlapping to cover the whole shell. Sprinkle with the Traeger garlic and chili pepper rub on all sides.
5. Cook to Perfection:
   Place shells on the smoker and cook for 1 hour 30 minutes to 2 hours, or until bacon is crisp and internal temp reaches 165°F. Brush with BBQ sauce during the last 15 minutes.
6. Finishing Touches:
   Let rest for 5–10 minutes off the heat to firm up slightly before serving.
7. Serve and Enjoy:
   Plate up with extra sauce on the side and enjoy the smoky, cheesy, bacon-wrapped goodness.

Texture & Flavor Secrets

The magic of smoked shotgun shells lies in the contrast — crisp, smoky bacon wrapping around tender pasta filled with spicy, juicy meat and oozing cheese. The BBQ glaze adds a sticky, sweet finish that brings everything together. Each bite delivers smoky heat, creamy richness, and that satisfying bacon crunch.

Cooking Tips & Tricks

Make your shotgun shells shine with these tips:

• Chill for a few hours or overnight before smoking to soften pasta.
• Use thin-sliced bacon so it crisps up evenly.
• Don’t overfill the shells or the meat will push out as it cooks.
• Flip carefully with tongs to avoid tearing.

What to Avoid

A few things can throw off your shells — here’s how to avoid them:

• Using thick-cut bacon: It won’t crisp properly before the inside is done.
• Skipping the rest time: Pasta won’t cook through as well.
• Adding BBQ sauce too early: It can burn. Glaze near the end.
• Overstuffing: Can cause bursting during smoking.

Nutrition Facts

Servings: 10
Calories per serving: 430

Note: These are approximate values.

Preparation Time

Prep Time: 30 minutes
Cook Time: 1 hour 45 minutes
Total Time: 2 hours 15 minutes

Make-Ahead and Storage Tips

You can fully assemble these shotgun shells a day in advance and refrigerate until you’re ready to smoke. This also helps the pasta absorb moisture and soften. Leftovers keep well in the fridge for 3–4 days and reheat best in the oven or air fryer to maintain that crispy bacon texture.

How to Serve Smoked Shotgun Shells

They’re perfect on their own, but here are some killer pairings:

• Serve with mac and cheese, potato salad, or grilled corn.
• Add a dipping sauce like ranch, chipotle mayo, or more BBQ sauce.
• Slice in half and serve as appetizers at your next party.

Creative Leftover Transformations

Turn those extras into something new and delicious:

• Chop and stuff into a hoagie roll with cheese for a smoky sandwich.
• Dice and mix into scrambled eggs or a breakfast burrito.
• Crumble over nachos or baked potatoes for BBQ-loaded toppings.

Additional Tips

Try soaking the manicotti shells in warm water for 15–20 minutes if you’re short on fridge time. It speeds up the softening process before smoking. For even more flavor, sprinkle extra rub just before glazing to build layers.

Make It a Showstopper

Drizzle with extra BBQ sauce and sprinkle chopped chives or jalapeño slices on top for a pop of color. Serve on a wooden board with a ramekin of dipping sauce for that full backyard BBQ vibe.

Variations to Try

• Mac & Cheese Shells: Mix in mac and cheese instead of meat for a gooey version.
• Tex-Mex Style: Add black beans, corn, and taco seasoning to the filling.
• Sweet Heat Glaze: Mix hot honey with BBQ sauce for a spicy-sweet twist.
• Breakfast Shells: Fill with sausage, egg, and cheese for a morning smoker hit.
• Low Carb: Use hollowed-out zucchini instead of pasta for a keto version.

FAQ’s

Q1: Can I use precooked manicotti shells?

A1: No need. Uncooked shells soften perfectly if refrigerated before smoking.

Q2: What’s the best wood for smoking?

A2: Hickory, apple, or pecan all work great for balanced smoke flavor.

Q3: Can I cook these in the oven?

A3: Yes! Bake at 375°F for about 45–55 minutes, finishing under the broiler.

Q4: Is the filling spicy?

A4: Mildly spicy, but you can reduce jalapeños or swap cheeses for less heat.

Q5: Can I freeze them?

A5: Absolutely. Freeze before smoking and thaw overnight before cooking.

Q6: How do I reheat leftovers?

A6: Use the oven or air fryer to keep the bacon crisp.

Q7: Can I use turkey bacon?

A7: Yes, but it may not crisp as well. Try baking at higher heat briefly.

Q8: Can I make them ahead?

A8: Yes, prep fully and refrigerate for up to 24 hours before smoking.

Q9: Should I parboil the shells?

A9: No need — the moisture from the meat softens them during rest and smoking.

Q10: What rub or sauce can I substitute?

A10: Use your favorite BBQ rub and sauce combo — sweet, smoky, or spicy.

Conclusion

Smoked shotgun shells are the kind of recipe that makes people stop and ask, “What is THAT?” From the first bite, you’ll get smoky, spicy, creamy, cheesy, and crispy all in one. Whether you’re feeding a crowd or treating yourself, this dish delivers big BBQ energy with just the right amount of kick. Go on, fire up the smoker — your taste buds are in for a ride.

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