The town fair was alive with music and laughter that July afternoon when I bumped into my old college roommate, Joe, by the barbecue tent. He tossed me a smoked “shotgun shell” wrapped in bacon, stuffed pasta shell bursting with gooey cheese and seasoned meat. That one bite, smoky and savory, instantly transported me back to our dorm kitchen experiments, where we’d wrap everything in bacon just to see what happened.
Months later, I decided to recreate it at our annual family reunion held at my sister’s lakeside cottage. Early morning, the smoke from my portable smoker curled up around the pines while kids fished and adults lounged by the water.
My daughter, the one who always nibbles first, scooped one up, they disappeared faster than hotcakes on the griddle. My husband clapped me on the back so hard he nearly twirled me in laughter. Even our elderly neighbor, who usually complains about too much smoke, leaned over and asked for “just one more.”
Now, here I am, retired and loving every minute of playing with recipes that blend comfort, flair, and a little nostalgia. Smoked Shotgun Shells Bacon is my version of that fair-time discovery, a hearty bite with pasta, meat, cheese, and that irresistible bacon cuddle. It’s simple enough for a cozy weeknight yet impressive enough for a holiday gathering.
Short Description
Hearty manicotti stuffed with seasoned beef, sausage, cream cheese, cheddar, and jalapeño, wrapped in bacon and smoked low and slow for a crispy, melty, flavor-packed appetizer or dinner treat.
Key Ingredients
- 16 oz manicotti shells (two 8‑oz boxes)
- 1.5 lb ground beef
- 1 lb hot Italian sausage
- 1 medium onion, finely diced
- 2 cups sharp cheddar cheese, shredded
- 6 oz cream cheese, softened
- 1 jalapeño, finely diced
- 2 tsp Slap Ya Mama seasoning
- 2 tsp garlic powder
- 2 tsp black pepper
- 1 tsp red pepper flakes
- 1/3 cup barbecue sauce
- 32 oz bacon (two 16‑oz packs; more if needed)
- Additional barbecue sauce for basting
Tools Needed
- Large mixing bowl
- Skillet or frying pan
- Smoker (or grill with lid)
- Tongs and basting brush
- Sheet pan or foil-lined tray
- Small spoon or piping bag for filling
Cooking Instructions
Step 1: Prep the Filling
Combine ground beef, sausage, cheddar, cream cheese, onion, jalapeño, Slap Ya Mama, garlic powder, pepper, red pepper flakes, and barbecue sauce in a large bowl. Use your hands to mix gently until evenly combined—don’t overwork it, or the filling may become tough.
Step 2: Stuff the Shells
Take uncooked manicotti shells and fill them from both ends using a small spoon or your fingers. Fill them until firm but easy—avoid overstuffing, so shells don’t crack and fillings stay tender inside.
Step 3: Wrap in Bacon
Cut bacon to fit around each shell, overlapping slightly if needed. Wrap completely, covering ends too. A single thick strip works well, or double-wrap with thinner slices for extra flavor.
Step 4: Preheat the Smoker
Set your smoker (or grill) to 250°F. Use a tray or clean rack to hold the bacon-wrapped shells.
Step 5: Smoke the Shells
Smoke for 60 minutes, then flip each shell. Baste with barbecue sauce to build a glossy, flavorful layer. Continue smoking another 60 minutes—or until bacon is golden brown and crisp, cheese is bubbling, and pasta shell is tender.
Step 6: Serve Hot
Use tongs to transfer shells to a platter. Drizzle with more barbecue sauce, and serve immediately—smoky, hot, and utterly irresistible.
Why You’ll Love This Recipe
Flavor Explosion: Smoked bacon meets spicy sausage, creamy cheeses, and jalapeño kick.
Hands-On Fun: Great for gatherings—guests love picking their own shotgun shell.
Balanced Comfort: Pasta offers hearty warmth while sausage and peppers add spice.
Prep-Ahead Friendly: Assemble earlier and smoke fresh when guests arrive.
Show-Stopper Appeal: Looks gourmet but is easy to make in batches.
Mistakes to Avoid & Solutions
Overfilling shells: They may burst or overflow.
Solution: Leave a little space at the ends.
Tight bacon wrapping: Can split during smoking.
Solution: Wrap snugly but allow a small overlap.
Smoking too hot: Shells cook unevenly, cheese leaks.
Solution: Maintain a steady 250°F smoker temperature.
Skipping the flip: Bacon may burn on one side.
Solution: Flip halfway and baste well.
Undercooked filling: Cold spots inside.
Solution: Check center temperature with thermometer—should be 165°F.
Serving and Pairing Suggestions
Serve family-style on a wooden board, garnished with chopped parsley.
Offer dipping sauces: smoky BBQ, ranch, or spicy mustard.
Side pairings: fresh coleslaw, grilled corn salad, or a green garden salad.
Beverage suggestions: ice-cold beer, iced tea, or a light red wine.
Perfect for game nights, backyard cookouts, or holiday appetizers.
Storage and Reheating Tips
Refrigerate: Store in airtight container up to 3 days.
Reheat: Warm in a 350°F oven for 10–12 minutes until heated.
Freeze: After smoking and cooling, freeze individually on a tray then pack in freezer bags. Reheat at 350°F for 20–25 minutes from frozen.
Avoid soggy bacon: Re-crisp under broiler for 1–2 minutes after reheating.
FAQs
1. Can I bake these instead of smoking?
Yes, bake at 375°F for 25–30 minutes, flipping halfway, and brush with barbecue sauce.
2. Can I use mild sausage instead?
Absolutely, substitute hot sausage with mild for less spice.
3. Can I prep these ahead?
Fill and wrap in the morning, refrigerate, then smoke later in the day.
4. What if bacon shrinks and reveals the shell?
Wrap with slightly longer strips or double-wrap.
5. How spicy are these?
Moderately spicy from jalapeño and seasoning, you can halve the jalapeño for milder heat.
Tips & Tricks
Chill the filling for 30 minutes before stuffing for cleaner handling.
Precook shells halfway in boiling water (5 minutes) if worried about underdone pasta.
Use hickory or applewood chips for a balanced smoky flavor.
Line the smoker tray with foil for easier cleanup.
Let the shells rest 5 minutes after smoking—cheese settles and flavors meld.
Recipe Variations
Vegetarian option: Replace meat with sautéed mushrooms, spinach, and plant-based sausage. Mix with feta in place of cream cheese.
Cheesy jalapeño twist: Add pepper jack cheese and extra diced jalapeños—double the kick in every bite.
Italian-inspired: Swap BBQ sauce for marinara, use Italian seasoning, and wrap in prosciutto instead of bacon.
Spicy maple glaze: Brush with maple syrup mixed with chili flakes in the last 10 minutes of smoking for sweet‑heat balance.
Final Thoughts
The funny thing is, Joe never gave me the actual recipe for those bacon-wrapped beauties at the fair, just that one perfect bite and a wink that said, “Figure it out.” So I did, in my own way, surrounded by family, lakeside laughter, and the occasional splash from a rogue water balloon.
My sister now requests Smoked Shotgun Shells Bacon for every reunion, my grandkids call them “meat noodles,” and even my picky nephew asked for seconds (which, in this house, is high praise). They may have started as a spontaneous bite on a summer afternoon, but now they live on in smoky, cheesy, bacon-wrapped glory—shared, devoured, remembered.
Smoked Shotgun Shells Bacon
Print ThisIngredients
- 16 oz manicotti shells (two 8‑oz boxes)
- 1.5 lb ground beef
- 1 lb hot Italian sausage
- 1 medium onion, finely diced
- 2 cups sharp cheddar cheese, shredded
- 6 oz cream cheese, softened
- 1 jalapeño, finely diced
- 2 tsp Slap Ya Mama seasoning
- 2 tsp garlic powder
- 2 tsp black pepper
- 1 tsp red pepper flakes
- 1/3 cup barbecue sauce
- 32 oz bacon (two 16‑oz packs; more if needed)
- Additional barbecue sauce for basting
Instructions
Step 1: Prep the Filling
Mix ground beef, sausage, cheeses, onion, jalapeño, seasonings, and BBQ sauce until combined. Don’t overmix.
Step 2: Stuff the Shells
Fill uncooked manicotti from both ends until packed but not bursting.
Step 3: Wrap in Bacon
Wrap each shell fully in bacon, covering the ends. Use one or two strips per shell as needed.
Step 4: Preheat the Smoker
Set smoker (or grill) to 250°F. Place shells on a clean rack or foil-lined tray.
Step 5: Smoke the Shells
Smoke for 60 minutes, flip, brush with BBQ sauce, and smoke another 60 minutes until bacon is crisp and cheese bubbly.
Step 6: Serve Hot
Plate immediately, drizzle with extra BBQ sauce, and enjoy.
