This recipe is pure BBQ brilliance. The name “shotgun shells” comes from the pasta shells resembling shell casings once they’re filled, wrapped, and smoked. But really, they’re just an incredible mash-up of cheesy meatballs, smoky bacon, and BBQ pasta all rolled into one glorious bite.
The first time I made these, it was for a backyard cookout, and I swear they vanished before I could even grab a second one. They’re that kind of snack. Smoky, cheesy, sticky, savory, and just a little sweet—total flavor bomb.
Why You’ll Love This Recipe
- Smoky, cheesy, savory, sweet—it hits every flavor note.
- Perfect for the smoker—low and slow gives them incredible texture and taste.
- Great for parties—prep ahead, then smoke while you mingle.
- Customizable—use ground beef, turkey, chicken, or even plant-based meats.
- Crowd-pleaser—a BBQ appetizer that’s impossible to resist.
Prep Time and Servings
- Total Time: 2½–3 hours (including smoking)
- Active Prep Time: 30 minutes
- Servings: 6–8 as an appetizer
- Calories per shell: ~300
- Protein: 16g | Carbs: 12g | Fat: 20g
Ingredients
- 1 box (about 20) uncooked manicotti shells (dry)
- 1 lb ground beef or ground turkey
- ½ lb ground sausage (turkey or beef)
- 1 cup shredded cheddar or mozzarella cheese
- ¼ cup cream cheese (softened)
- 1 teaspoon garlic powder
- 1 teaspoon onion powder
- ½ teaspoon smoked paprika
- Salt and pepper, to taste
- 10–12 slices beef or turkey bacon (halal-friendly)
- ½ cup BBQ sauce (plus extra for glazing)
Optional Add-Ins
- Diced jalapeños (for heat)
- Green onions
- Shredded pepper jack cheese
- Crumbled cooked turkey bacon inside the mix for even more flavor
Step-by-Step Instructions
Step 1: Make the Filling
- In a large bowl, combine ground meat, sausage, cream cheese, shredded cheese, and seasonings.
- Mix until fully combined, but don’t overwork it—just enough to bring it together.
Tip: Use gloves or a spoon—this mixture gets sticky.
Step 2: Stuff the Shells
- Carefully fill each uncooked manicotti shell with the meat mixture.
- You can use your hands, a piping bag, or a zip-top bag with the corner cut off.
Pro Tip: Don’t overfill—leave a little room at each end for the bacon to seal in the filling.
Step 3: Wrap with Bacon
- Wrap each shell with a slice of bacon, spiraling it around to cover the entire shell.
- If using thinner bacon, you may need 1½ slices per shell.
- Place seam-side down on a tray or baking sheet.
Step 4: Rest and Chill
- Let the wrapped shells rest in the fridge for at least 4 hours, or ideally overnight.
- This allows the pasta to soften from the moisture in the meat and makes the final texture perfect.
Shortcut? You can soak the shells in warm water for 20 minutes if short on time, but chilling is best.
Step 5: Smoke the Shells
- Preheat your smoker to 250°F. Use wood chips like hickory, apple, or pecan for great flavor.
- Place the shotgun shells directly on the smoker grates or a wire rack.
- Smoke for 90 minutes, then begin brushing with BBQ sauce.
- Continue smoking for another 30–45 minutes, brushing with more sauce every 15 minutes.
Target internal temp: 165°F in the center of the filling.
Step 6: Glaze and Rest
- In the last 10 minutes, turn up the heat to 275°F to help set and caramelize the sauce.
- Once done, let them rest for 5–10 minutes before serving.
Optional: Sprinkle with extra cheese in the final 10 minutes for a melty topping.
How to Serve
- As an appetizer: Cut into halves or thirds and serve with extra BBQ sauce.
- As a main: Serve 2–3 shells per person with slaw or potato salad.
- On a party platter: Pair with pickles, grilled corn, and dipping sauces.
- In a wrap: Slice and stuff into a tortilla with lettuce, jalapeños, and more sauce.
Additional Tips
- Let them chill: Refrigerating helps soften the pasta and makes stuffing easier.
- Use indirect heat: Keeps the bacon from burning before the filling is fully cooked.
- Want crispier bacon? Finish the shells in a hot oven or under the broiler for 2–3 minutes.
- Cheese matters: Use a blend of mozzarella (for melt) and cheddar (for flavor).
- Make ahead: Assemble the day before and smoke when ready.
Recipe Variations
- Tex-Mex Style: Add taco seasoning and shredded pepper jack to the filling. Serve with chipotle ranch.
- Breakfast Version: Use turkey breakfast sausage, scrambled egg, and cheese inside.
- Spicy BBQ: Add hot sauce or cayenne to the filling and use a spicy BBQ glaze.
- Low-carb version: Use thinly sliced zucchini or eggplant in place of pasta shells.
- Vegetarian Option: Use a plant-based ground meat alternative and veggie bacon.
Storage & Reheating
- Fridge: Store in an airtight container for up to 3 days.
- Reheat: Bake at 350°F or reheat in the smoker until warmed through.
- Freezer: Freeze uncooked wrapped shells for up to 2 months. Thaw overnight before smoking.
Special Equipment
- Smoker (pellet grill, offset, or electric)
- Digital meat thermometer
- Wire rack (optional but helps with airflow and easy transfer)
FAQ
Can I use pre-cooked pasta shells?
No—use dry, uncooked manicotti shells. The filling’s moisture will soften them perfectly as they smoke.
What kind of meat is best?
A mix of ground beef and sausage adds the most flavor and fat for tenderness.
Is turkey bacon OK?
Absolutely. It crisps a little differently than pork bacon but still wraps well and adds smoky flavor.
Can I cook these in the oven?
Yes—bake at 350°F for 45–50 minutes, then broil to crisp the bacon and caramelize the sauce.
How do I know when they’re done?
Use a meat thermometer to ensure the filling hits 165°F internally.
Conclusion
Smoked Shotgun Shells are cheesy, meaty, smoky, BBQ-glazed bites of heaven—everything you want in a finger food or casual main dish. They look impressive, taste incredible, and are surprisingly easy to make. Once you try them, they’ll be your new favorite go-to for cookouts, game days, and backyard hangouts.
Give them a try, and don’t forget to snap a pic and tag me—I have to see those smoky, melty, bacon-wrapped beauties!
