Smoked Shotgun Shells Bacon is one of those dishes that brings the best of Southern backyard gatherings right into your mouth. I first made these at my neighbor Earl’s family reunion—smoke drifting through the yard, laughter from the kids splashing at the hose, and me fumbling with filling manicotti shells and wrapping them in bacon.

At first, folks raised eyebrows, but once those shells hit the smoker for two hours, each bite turned skeptics into fans. Crispy bacon, smoky sausage and beef filling, creamy cheese, and a spicy hint from jalapeños—it felt like every flavor I loved wrapped up in one perfect package.

Later on, I brought them to a football watch party, and people were practically wrestling for them. One friend said eating one felt like “a full meal in a shell.” I’ll never forget hearing that while passing around another batch, smoke swirling overhead.

These shotgun shells became my favorite one when I want something impressive but uncomplicated—no fancy plating needed. It’s about shared grills, beat-up cast iron, and the simple joy of watching good food disappear fast. Now, I can’t wait to show you exactly how to make them at home.

Short Description

Smoked Shotgun Shells Bacon are bacon-wrapped, sausage-and-beef-filled manicotti smoked for two hours. Each bite offers a perfect balance of crispy, smoky, cheesy, and a hint of spice—ideal for casual gatherings or game-day snacking.

Key Ingredients

Pasta

16 ounces manicotti shells

Meat Filling

1.5 pounds ground beef
1 pound hot Italian sausage
1 medium onion, finely diced
2 cups shredded sharp cheddar cheese
6 ounces softened cream cheese
1 jalapeño, finely diced

Seasonings

2 teaspoons Slap Ya Mama seasoning
2 teaspoons garlic powder
2 teaspoons ground black pepper
1 teaspoon red pepper flakes

Other

¹⁄₃ cup barbecue sauce (plus extra for basting)
32 ounces sliced bacon

Tools Needed

Smoker, set to 250°F
Large bowl
Pastry brush
Baking sheet or tray
Clean hands or spatula for mixing

Cooking Instructions

Step 1: Preheat Smoker
Set the smoker to 250°F and wait until the temperature is stable and the smoke is clean.

Step 2: Make the Filling
In a bowl, combine ground beef, Italian sausage, diced onion, cheddar, cream cheese, jalapeño, Slap Ya Mama seasoning, garlic powder, black pepper, red pepper flakes, and ¹⁄₃ cup barbecue sauce. Mix well until evenly combined.

Step 3: Stuff the Shells
Gently fill each uncooked manicotti from both ends, ensuring they’re fully packed without air pockets.

Step 4: Wrap in Bacon
Wrap each stuffed shell completely with bacon slices—use two pieces if needed. Overlap ends and ensure full coverage.

Step 5: Baste with BBQ Sauce
Brush each bacon-wrapped shell with barbecue sauce to coat all sides. Place them on a tray.

Step 6: Smoke the Shells
Place shells in the smoker. Smoke for 60 minutes, then flip and baste again. Smoke for an additional 60 minutes or until bacon is crisp and filling is hot.

Step 7: Serve Hot
Remove the shells from the smoker and serve immediately. They’re rich and indulgent, so a fresh salad or light side complements them well.

Why You’ll Love This Recipe

Flavor Explosion: Smoky, spicy, cheesy beef and sausage wrapped in bacon delivers satisfying richness.

Make-Ahead Friendly: Fill and wrap ahead, then smoke when guests arrive.

Show-Stopping Appeal: These are conversation starters at any gathering.

Kid & Crowd Pleaser: Comforting flavors with a gentle spice kick.

Customizable Heat: Adjust jalapeño or seasoning for milder or bold taste.

Mistakes to Avoid & Solutions

Soggy Bacon:
Solution: Smoke at a steady 250°F and don’t rush—crispy texture takes full two hours.

Uncooked Filling:
Solution: Ensure shells are tightly packed and reach internal temp of 165°F.

Shell Breakage:
Solution: Handle gently when stuffing and wrapping. Avoid overstuffing.

Flavorless Shells:
Solution: Mix spices and BBQ sauce thoroughly into filling. Brush shells well before smoking.

Shells Sticking Together:
Solution: Place shells spaced apart on tray; don’t stack.

Serving and Pairing Suggestions

Serve hot with extra barbecue sauce on the side.

Pair with potato salad, coleslaw, or cornbread for a Southern-style spread.

Great at buffets, arrange them on a platter and let guests grab and go.

Complement with iced tea, cold beer, or lemonade to balance richness.

Storage and Reheating Tips

Store: Cool to room temperature, then refrigerate in airtight container for up to 3 days.

Reheat in Oven or Smoker: Reheat at 300°F for 15–20 minutes until warmed through.

Avoid Microwave: Microwaving ruins bacon texture.

Freeze: Wrapped shells freeze well up to 2 months. Defrost overnight and reheat in oven/smoker.

FAQs

1. Can I use cooked pasta shells?
No, use uncooked—shells expand as they cook in the smoker and hold the filling better.

2. Can I make these without a smoker?
Yes, bake at 300°F for about 90 minutes with a bit of liquid smoke for flavor.

3. Are they very spicy?
Mild heat from jalapeño and red pepper flakes, reduce or omit if preferred.

4. What’s “Slap Ya Mama”?
A Southern spice blend, substitute with Cajun or Creole seasoning if needed.

5. Can I use turkey sausage instead?
Yes, use turkey sausage; the flavor might be milder, so adjust spices and sauce accordingly.

Tips & Tricks

Mix filling with hands for even texture and seasoning.

Chill stuffed shells before wrapping to help bacon adhere.

Use thick-cut bacon for sturdiness and better smoke absorption.

Rotate shells during smoking for even crispiness.

Let rest a few minutes after smoking; juices redistribute and filling firms slightly.

Recipe Variations

Cheesy Ranch Shotgun Shells
Use ranch seasoning in place of Slap Ya Mama. Stir in shredded Monterey Jack cheese. Baste with ranch-infused barbecue sauce.

Mexican-Style Shells
Add chopped cilantro, cumin, and diced green chiles to the filling. Top bacon-wrapped shells with cotija and squeeze lime after smoking.

Buffalo Shells
Mix in buffalo sauce and blue cheese crumbles into the filling. Baste with buffalo-infused BBQ sauce and serve with ranch dipping sauce.

Vegetarian Version
Omit meats, use 2 cups cooked lentils, 1 pound crumbled tempeh, and extra veggies. Wrap in vegetarian bacon or thin eggplant slices and follow the same smoke steps.

Final Thoughts

Smoked Shotgun Shells Bacon are bold, comforting, and perfect for sharing around firelight or smoke. Each bite is that smoky-bacon hug we all crave. I’ve served them at family reunions, weekend grilling, and tailgate parties—and they always disappear first.

I hope these become a star in your cooking rotation, bringing smoky fun and good conversation to your table. Let that bacon crisp, that filling melt, and enjoy every satisfying bite.

Smoked Shotgun Shells Bacon Recipe

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Nutrition facts: calories fat

Rating: 5.0/5

( 1 voted )

Ingredients

Pasta
16 ounces manicotti shells
Meat Filling
1.5 pounds ground beef
1 pound hot Italian sausage
1 medium onion, finely diced
2 cups shredded sharp cheddar cheese
6 ounces softened cream cheese
1 jalapeño, finely diced
Seasonings
2 teaspoons Slap Ya Mama seasoning
2 teaspoons garlic powder
2 teaspoons ground black pepper
1 teaspoon red pepper flakes
Other
¹⁄₃ cup barbecue sauce (plus extra for basting)
32 ounces sliced bacon

Instructions

Step 1: Preheat Smoker
Set smoker to 250°F and let it reach a steady temperature.

Step 2: Mix the Filling
Combine all meats, cheeses, onion, jalapeño, seasonings, and ¹⁄₃ cup BBQ sauce in a bowl. Mix well.

Step 3: Fill the Shells
Stuff uncooked manicotti from both ends until fully packed.

Step 4: Wrap in Bacon
Wrap each shell in bacon, overlapping if needed for full coverage.

Step 5: Baste with Sauce
Brush all sides with barbecue sauce. Set on a tray.

Step 6: Smoke
Smoke for 1 hour. Flip, baste again, and smoke 1 more hour until bacon is crisp.

Step 7: Serve
Serve hot with a fresh salad or light side.