Late last summer, our neighborhood started hosting weekend block parties, and everyone brings their best dish. My neighbor Dave, an amateur pitmaster with a smoker always humming, handed me a curious appetizer one evening: bacon-wrapped manicotti stuffed with spicy sausage and beef. He called them “Shotgun Shells,” and once I bit into that smoky, rich flavor-packed bundle, I knew I needed to recreate them for my family.

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The following Saturday, with my husband manning the smoker, we tackled these together in our backyard. The kids watched, fascinated by the hissing smoke and the sizzling bacon. My son, who usually shies away from anything too spicy, poked at one shell and exclaimed, “This is better than pizza!”

My daughter, busy documenting for me, snapped photos between bites (you’re welcome, Instagram). That afternoon buzzed with laughter, shared memories, and that irresistible aroma wafting through the yard. By dinner, those smoky shells had everyone smiling—a simple dish that had unexpectedly become the star of our summer nights.

Short Description

Smoked Shotgun Shells Bacon are bacon-wrapped, smoke-infused manicotti shells filled with a spicy beef-and-sausage mix—meaty, cheesy, and perfect for gatherings or family barbecues.

Key Ingredients

16 oz manicotti shells
1½ lb ground beef
1 lb hot Italian sausage
1 medium onion, finely diced
2 cups shredded sharp cheddar cheese
6 oz cream cheese, softened
1 jalapeño, finely diced
2 tsp Slap Ya Mama seasoning
2 tsp garlic powder
2 tsp ground black pepper
1 tsp red pepper flakes
⅓ cup barbecue sauce
32 oz sliced bacon
Extra barbecue sauce for basting

Tools Needed

Smoker (set to 250°F)
Large mixing bowl
Large spoon or hands (for mixing)
Pastry brush
Baking sheet or smoker rack

Cooking Instructions

Step 1: Preheat Smoker
Set smoker to 250°F (121°C) and let it stabilize before using.

Step 2: Make the Filling
In a large bowl, mix ground beef, Italian sausage, diced onion, cheddar, cream cheese, jalapeño, Slap Ya Mama seasoning, garlic powder, black pepper, red pepper flakes, and ⅓ cup barbecue sauce thoroughly.

Step 3: Stuff Shells
Fill uncooked manicotti shells from both ends, pressing gently to eliminate air pockets and ensure even meat distribution.

Step 4: Wrap in Bacon
Wrap each stuffed shell tightly with bacon, overlapping to cover completely. Use two strips if needed. Secure ends to prevent unraveling.

Step 5: Baste
Brush each shell with barbecue sauce, coating all sides.

Step 6: Smoke – First Hour
Arrange shells evenly on smoker rack or baking sheet. Smoke for 60 minutes, until bacon begins rendering and smoke ring appears.

Step 7: Baste and Smoke – Second Hour
Flip shells and baste again. Continue smoking another 60 minutes, or until bacon is crisp and fully rendered.

Step 8: Serve
Remove from smoker and serve hot—best when fresh off the rack.

Why You’ll Love This Recipe

Major Flavor Blast: Meaty, smoky, spicy, cheesy—all in one bite.

Make-Ahead Appetizer: Prep the filling and wrap ahead, smoke session when you’re ready.

Party Favorite: Unusual, fun presentation that guests love.

Kid-Tested: Even picky eaters enjoy the bacon and cheese with hidden flavor.

Protein Packed: Hearty and satisfying—works as a side or main depending on portion size.

Mistakes to Avoid & Solutions

Bacon Unravels: Trim ends flush and overlap coverage. Use a toothpick or chill wrapped shells before smoking.

Overstuffed Shells: Too much filling can crack shells. Stuff gently, press to fill but don’t force.

Dry Filling: Include cream cheese and bbq sauce to add moisture.

Uneven Smoking: Space shells with room between for even smoke exposure.

Undercooked Bacon: Smoke slow and low, crisp texture needs time, avoid rushing.

Serving and Pairing Suggestions

Serve in a basket to start a backyard gathering.

Pair with coleslaw, baked beans, or grilled corn.

Offer dipping sauces: extra barbecue sauce, ranch, or spicy mustard.

Present family-style on large platters so everyone can grab a couple.

Storage and Reheating Tips

Refrigerate cooled shells in airtight container up to 3 days.

Reheat in foil at 325°F oven for 10–12 minutes until warm.

Crisp back in smoker or grill for 10 minutes to revive bacon texture.

Freeze uncooked wrapped shells; thaw overnight, then smoke as usual.

FAQs

1. Can I bake instead of smoke?
Yes, bake at 375°F for about 45–55 minutes, flipping halfway and basting once.

2. Can I make them milder?
Leave out jalapeños and red pepper flakes, and use mild sausage.

3. Can I prep shells ahead?
Absolutely, assemble and refrigerate up to 24 hours before smoking.

4. What woods give best flavor?
Apple or cherry wood adds a sweeter touch, it pairs well with barbecue sauce.

5. Can I use bacon substitutes?
Turkey bacon works but wraps more thinly and needs careful basting to avoid drying.

Tips & Tricks

Chill filled shells before wrapping for easier handling.

Double-baste halfway through for rich, glossy exterior.

Reserve some cheddar inside for extra cheesy center.

Rotate shells in smoker to ensure even color and texture.

Brush shells with neutral oil before wrapping bacon if shells stick.

Recipe Variations

Cheesy Jalapeño Popper Shells
Use mild sausage, add cream cheese and cheddar blend, include chopped pickled jalapeños, wrap in bacon and smoke the same way.

BBQ Brisket Shells
Sub brisket burnt ends for sausage—same seasoning and wraps, smoke for 90 minutes, baste generously.

Turkey Bacon Version
Swap ground turkey and turkey bacon, use less cheese to lighten fat, smoke 45 minutes, then crisp in oven.

Veggie Boost Shells
Add finely chopped bell pepper, shredded zucchini, or spinach in the meat mix for extra veggies.

Final Thoughts

Creating these Smoked Shotgun Shells Bacon brought back that block-party spirit, stand-around-the-smoker laughter, and the thrill of unveiling something unexpected. When I served them at our last cookout, neighbors leaned in, eyes wide, smiles bigger, and no one could stop talking about the flavors.

Now, every time I fire up the smoker, I plan these shells first—simple to prep, rewarding to smoke, and always disappearing fast. They remind me that good food makes great memories, and for my family and friends, these smoky, savory shells are memory-makers every single time.

Smoked Shotgun Shells Bacon