Smoked Shotgun Shells

Shotgun Shells (Smoked Bacon-Wrapped Stuffed Pasta)

Exploring BBQ Staff
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Viral for good reason—Shotgun Shells are manicotti tubes stuffed with a cheesy sausage filling, wrapped in bacon, and smoked until the pasta turns tender and the bacon turns mahogany and crisp. Finish with a sticky glaze and watch the tray vanish.
Born on backyard pits and BBQ socials, this mash-up appetizer riffs on jalapeño-popper flavors and Texas smoke. The trick: soften the pasta and render the bacon without losing structure—this method nails both.
Prep Time 30 minutes
Cook Time 1 hour
Chill time 12 hours
Total Time 13 hours 30 minutes
Servings: 8 Servings
Course: Appetizers
Cuisine: BBQ & Grilling

Ingredients
  

Smoked Shotgun Shells
  • 1 Box manicotti shells about 14 pieces, 8 oz — 227 g
  • 1 lb Thin-cut bacon 14–16 slices — 454 g
  • 1 lb Pork sausage or 50/50 sausage + ground beef — 454 g
  • 8 oz Cream cheese softened — 226 g
  • 1 cup Shredded sharp cheddar ~113
  • ½ cup Shredded Monterey Jack or pepper jack 55 g
  • ¼ cup Pickled jalapeños or Fresh diced — 60 ml (optional, to taste)
  • 2 tbsp BBQ rub divided 16 g
Glaze
  • ½ cup BBQ Sauce
  • 1 tbsp Honey or hot honey to taste

Equipment

  • Large mixing bowls
  • Piping Bag or Zip top bag
  • Sheet pan
  • Measuring spoons
  • Kitchen Scale

Method
 

Soak shells (prevents cracking):
  1. Submerge manicotti in warm water (not boiling) 25–35 minutes until just pliable.
  2. Drain well on towels.
Preheat pit:
  1. Set smoker to 275–300°F (135–149°C) with indirect heat and mild wood.
Make filling:
  1. In a bowl, mix sausage, cream cheese, cheddar, Monterey/pepper jack, jalapeños, garlic powder, onion powder, black pepper, and 1 tbsp BBQ rub until cohesive.
Fill shells:
  1. Pipe filling into each shell from both ends so there are no air gaps (full but not bursting).
Wrap:
  1. Spiral-wrap each shell with 1 slice thin bacon (overlap slightly).
  2. If your shells are long, use 1½ slices.
Season:
  1. Place on a rack over a sheet pan; dust lightly with the remaining 1 tbsp BBQ rub.
Smoke:
  1. Transfer rack to the smoker; cook 90–120 minutes until bacon is deep golden/mahogany and the filling reads 165°F internally.
Glaze:
  1. Stir BBQ sauce + honey;
  2. brush during the last 10–15 minutes to set a shiny, tacky glaze.
Rest & serve:
  1. Rest 5–10 minutes; slice in halves if you want more pieces per tray.
Oven option (less smoke, still tasty):
  1. Bake at 375°F (190°C) for 35–45 minutes on a rack over a sheet pan until bacon is crisp and centers hit 165°F.
  2. Broil 1–2 minutes to finish; glaze in the last 5–7 minutes.

Notes

Description of the Finished Dish

A glossy, mahogany-crisp bacon jacket around tender pasta, stuffed with creamy, cheesy sausage and finished with a sweet-smoky glaze—rich, salty, tangy, and dangerously snackable.

Doneness & Texture Cues

  • Pasta: Tender with a little bite—no chalky center.
  • Bacon: Crisp edges, rendered fat, deep bronze color.
  • Filling: Set and juicy; thermometer slides in easily and reads ≥165°F.

Pro Tips

  • Soak vs. rest: Instead of soaking, you can fill shells and refrigerate 4–6 hours (or overnight)—the pasta hydrates from the filling and softens on the pit.
  • Thin bacon wins: Thin slices crisp faster at 275–300°F; thick-cut can stay rubbery.
  • Keep them upright: A rack prevents flat spots and helps even rendering.
  • Tidy ends: Wipe excess filling from ends so it doesn’t burn before the bacon sets.

Serving Suggestions

  • Serve with Classic Texas BBQ Sauce for sweet heat or a side of White BBQ Sauce for tang.
  • Pair on a platter with Pig Shots and Smoked Mac & Cheese for the ultimate party tray.

Variations

  • Buffalo Shells: Swap BBQ glaze for Buffalo + ranch drizzle; use Monterey/pepper jack.
  • Street-Corn Shells: Mix ¼ cup roasted corn and 1 tsp chili-lime seasoning into the filling; finish with cotija.
  • Breakfast Shells: Use maple breakfast sausage, add 2 tbsp diced green onion, and glaze with maple-BBQ.

Storage & Make-Ahead

  • Make-ahead: Fill and wrap up to 24 hours ahead; refrigerate uncovered for 1 hour to set, then cover.
  • Fridge (cooked): 3 days; reheat at 350°F (177°C) for 10–12 minutes to re-crisp bacon.
  • Freeze (cooked): Up to 1–2 months; thaw overnight and reheat as above. (Raw filled shells don’t freeze well—pasta can crack.)

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