What Are Smoked Shotgun Shells?

Smoked shotgun shells are a bold and indulgent BBQ appetizer made by stuffing uncooked pasta shells—typically manicotti—with a seasoned meat and cheese mixture, wrapping them in bacon, and slowly smoking them until perfectly crisp and savory. The name comes from their cylindrical shape resembling shotgun shells and their explosive flavor.

Golden bacon-wrapped bites sizzling on a charcoal grill with smoky heat rising in the background

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These shells are then brushed with barbecue sauce and finished in the smoker, giving them a rich, smoky crust and juicy center. With their unique texture and layered taste, they’re a guaranteed crowd-pleaser at any backyard cookout or tailgate party.

Why You’ll Love This Recipe

Combines the richness of BBQ meats with creamy, cheesy filling
Delivers a perfect smoke ring and bacon crisp when done right
Customizable with different proteins, cheeses, or spice levels
Easy to prep in advance and throw on the smoker day-of
A show-stopper appetizer for BBQ competitions, parties, and gamedays

Whether you’re hosting friends or trying something new on your pellet grill, this recipe brings serious wow factor.

Occasions to Serve Smoked Shotgun Shells

Smoked shotgun shells are best suited for:

Game day spreads and tailgates
Backyard BBQ parties
Cookout potlucks
Holiday smokers
Meat-lovers’ appetizers or hearty snacks

They’re ideal for feeding a crowd and hold up well on the smoker alongside ribs, brisket, or wings.

Preparation Phase

Making perfect smoked shotgun shells starts with the right preparation. While the recipe is simple, attention to detail in these early steps ensures your shells come out fully cooked, tender, and packed with smoky flavor.

Soaking the Pasta Shells

Some recipes skip soaking altogether; others suggest a 30–60 minute soak in warm water
Soaking helps soften the shells slightly and can ensure even cooking
Avoid over-soaking—they’ll tear during stuffing

Setting Up Your Smoker

Preheat smoker to 250–275°F
Choose woods like hickory, mesquite, cherry, or pecan for strong smoke flavor
Set up for indirect heat (essential for even smoking)

Filling Prep

Combine your meats, cheeses, and seasoning thoroughly
Use a piping bag or plastic zip-top bag for cleaner stuffing
Place everything within reach to streamline the wrapping process

Essential Tools and Equipment

Pellet smoker or grill (Traeger, Pit Boss, etc.)
Aluminum foil or baking sheet for easy cleanup
Meat thermometer for food safety
Sharp knife and cutting board
Mixing bowls and spatula
Pastry brush (for BBQ sauce)
Nitrile gloves for clean handling

Importance of Each Tool

The smoker is key to building layered flavor
Thermometer ensures meat reaches a safe internal temp (165°F)
Foil or trays prevent bacon grease flare-ups and keep your smoker cleaner
A pastry brush lets you coat shells with sauce evenly without disturbing bacon

Ingredients for Smoked Shotgun Shells

Main Ingredients

8–10 uncooked manicotti shells
1 lb ground beef or pork sausage (or 50/50 blend)
1 cup shredded cheddar cheese
4 oz cream cheese or ricotta
1 tbsp BBQ seasoning or rub
10–12 slices thick-cut bacon
½ cup BBQ sauce (for glazing)

Optional Add-ins

¼ cup chopped jalapeños
¼ cup diced onion
1 tsp hot sauce
½ tsp smoked paprika
¼ cup crumbled bacon (inside filling)

Step-by-Step Directions

1. Pre-Soak the Shells (Optional)

Soak manicotti shells in warm water for 30 minutes
Drain and pat dry with paper towels

Tip: Some skip soaking entirely and smoke longer to fully cook—test both methods to find your preference

2. Make the Meat Filling

In a large bowl, mix ground meat, shredded cheese, cream cheese, BBQ rub, and any optional ingredients
Combine thoroughly until evenly mixed
Transfer to a piping bag or large zip-top bag with corner cut off

3. Stuff the Shells

Pipe the meat mixture into each end of the shell until full
Be gentle to avoid cracking
Repeat until all shells are filled

4. Wrap with Bacon

Wrap each stuffed shell with 1–2 slices of thick-cut bacon
Ensure full coverage; overlap slightly for secure hold
Tuck or press ends so bacon stays tight

Tip: Chill for 1–2 hours (or overnight) to help bacon adhere and prevent unraveling during the smoke

5. Add a Rub Layer

Sprinkle more BBQ rub lightly over the bacon
This adds an extra layer of flavor and helps the bacon crisp

6. Smoke the Shotgun Shells

Preheat smoker to 250°F
Place shells on grates or baking sheet with rack
Smoke for 90–120 minutes, flipping once halfway

7. Glaze with BBQ Sauce

After 75–90 minutes, brush with BBQ sauce
Continue smoking for another 20–30 minutes until sauce sets and bacon is crisp

8. Check Internal Temperature

Use a thermometer to ensure filling hits 165°F
Bacon should be darkened, crisped, and slightly caramelized

9. Let Rest and Serve

Rest for 5–10 minutes
Slice in half or serve whole
Offer extra sauce on the side for dipping

Variation: Want extra crisp? Increase heat to 300°F in last 10 minutes or broil briefly

Serving Suggestions

When it’s time to serve smoked shotgun shells, presentation matters almost as much as flavor. These bacon-wrapped beauties deserve a mouthwatering display.

How to Serve Them

Whole: Serve shells whole as a protein-heavy appetizer or entrée.
Halved: Slice them in half for bite-size servings at parties or buffets.
Sauced or dry: Glaze with warm BBQ sauce just before serving or serve sauce on the side for dipping.
Plated presentation: Stack them pyramid-style on a platter and garnish with chopped parsley or green onions for contrast.

Best Dipping Sauces

Pair these smoky shells with rich, spicy, or tangy dips:

Classic BBQ sauce (sweet, smoky, or spicy)
Ranch dressing
Chipotle aioli
Creamy jalapeño dip
Garlic butter sauce
Spicy honey mustard
Beer cheese sauce

Tip: Warm your dipping sauces slightly before serving—cold sauces can dull the flavor and texture contrast.

8 Perfect Side Dishes

Smoked shotgun shells are rich and savory, so the ideal sides balance or enhance their flavor. Here are 8 side dish ideas that complete the meal.

1. Grilled Corn on the Cob

A smoky, charred sweetness that echoes the grill tones in the shells
Serve with chili-lime butter or crumbled cotija cheese

2. Classic Coleslaw

Crunchy and tangy, this cool side dish cuts through the heaviness
Use vinegar-based slaw for less richness

3. BBQ Baked Beans

Sweet, smoky, and hearty—perfect for soaking up extra sauce
Add bacon or brisket for more depth

4. Mac and Cheese

Ultra-creamy mac balances the smoky bacon with rich indulgence
Top with breadcrumbs for extra texture

5. Potato Salad

Creamy or mustard-based, it adds contrast in both flavor and temperature
Try with red potatoes and dill for a fresher version

6. Pickled Vegetables

Briny and acidic, they reset your palate between bites
Quick-pickled onions, cucumbers, or carrots work well

7. Garlic Bread

Soaks up the juices and leftover sauce
Adds crunch without competing with the bacon

8. Grilled Jalapeño Poppers

For the spice lovers, these mirror the meat-and-cheese core of shotgun shells
Add cream cheese filling for smooth heat

Common Mistakes to Avoid

Avoid these common errors to ensure your smoked shotgun shells turn out perfectly every time.

1. Not Soaking or Softening Shells

If left completely dry, the pasta may stay chewy even after a long smoke
Either soak or extend smoke time by 30–45 minutes

2. Overstuffing the Shells

Too much filling can cause blowouts or uneven cooking
Fill just to the edge of each shell, not past it

3. Using Thin Bacon

Thin bacon cooks too quickly and can burn or unravel
Always use thick-cut bacon for structure and texture

4. Smoking Too Hot

High temperatures (above 300°F) will burn the bacon before the meat cooks
Stay between 250–275°F for even results

5. Skipping the Chill Step

Wrapping and immediately smoking can cause bacon to separate
Chill for at least 1 hour (or overnight) to tighten the wrap

6. Not Flipping Midway

One side may cook faster and get crispy while the bottom stays soft
Flip halfway through for even texture

7. Not Using a Thermometer

You must ensure internal temp of 165°F for safe meat cooking
Don’t rely on time alone—check each piece if possible

8. Applying Sauce Too Early

BBQ sauce contains sugar and can burn if added too soon
Apply in the last 20–30 minutes of cooking

Recipe Tips for Success

These tips can take your smoked shotgun shells from good to unforgettable. Each one helps you get the most flavor, texture, and presentation from your cook.

Use a 50/50 Meat Blend

Combine ground beef and pork sausage for balance
Pork adds fat and flavor; beef adds structure

Choose the Right Cheese

Use a mix of melting cheese (cheddar, mozzarella) and binding cheese (cream cheese, ricotta)
This helps the filling stay together and stay creamy after smoking

Don’t Skip Resting Before Smoking

Letting shells chill after wrapping makes bacon adhere better
It also gives pasta time to soften slightly before the cook

Smoke Over Flavorful Wood

Best wood chips/pellets: hickory, cherry, mesquite, pecan
These pair well with both bacon and ground meats

Use a Cooling Rack Over a Pan

Place shells on a wire rack inside a sheet pan
Keeps bacon crisp and allows airflow while catching drips

Storage and Reheating Instructions

How to Store

Refrigerate: Store cooked shotgun shells in an airtight container for up to 4 days
Freeze (cooked): Let cool fully, wrap in foil, and place in freezer bags for up to 2 months
Freeze (uncooked): Wrap and freeze raw assembled shells for smoking later—thaw overnight before use

How to Reheat

Oven: Preheat to 350°F. Place shells on a baking sheet and bake 10–15 minutes until heated through
Air fryer: Reheat at 375°F for 5–7 minutes—restores crispiness
Skillet: Use low heat and cover with lid to avoid drying out
Avoid microwaving unless wrapped in a damp towel—results may be soft or soggy

Tip: Add a small bowl of water in the oven during reheating to prevent bacon from drying out

Frequently Asked Questions (FAQs)

Can you make smoked shotgun shells ahead of time?

Yes. Prep and assemble them up to 24 hours in advance. Store covered in the fridge and smoke when ready.

Do you have to pre-cook the pasta shells?

Not necessarily. Most recipes use dry manicotti shells, but pre-soaking or resting the wrapped shells overnight helps them soften during the cook.

What meat works best for shotgun shells?

Ground pork sausage, ground beef, or a blend. You can also use ground turkey or chicken, though you may need to increase fat content.

Can you bake them instead of smoking?

Yes. Bake at 375°F for about 40–45 minutes, flipping halfway and broiling at the end for a crisp finish.

Can I use turkey bacon?

You can, but it’s thinner and doesn’t wrap as well. Use toothpicks to secure and monitor closely to avoid burning.

How long do they take to smoke?

Between 90 to 120 minutes at 250–275°F. Thicker bacon may require slightly longer cooking time.

What internal temp should they reach?

Always cook until the internal temperature is 165°F at the center of the filling.

What’s the best wood for smoking shotgun shells?

Hickory and cherry are top choices. Mesquite adds boldness, while pecan gives a smooth, sweet-smoke profile.

Can I freeze them after cooking?

Yes. Wrap tightly in foil and freeze for up to 2 months. Reheat in oven or air fryer until hot and crisp.

Conclusion

Smoked shotgun shells are the ultimate union of barbecue technique, flavor, and visual impact. From their rich, smoky meat-and-cheese center to the crispy bacon exterior, every bite offers bold satisfaction. Whether you’re a backyard smoker enthusiast or a BBQ novice, this recipe is approachable, impressive, and perfect for any gathering.

With the right prep, quality ingredients, and smart cooking strategy, your shotgun shells will steal the show. Pair them with your favorite sides, sauces, and cold drinks, and you’ll have an unforgettable meal that guests will request again and again.

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