Smoked Shotgun Shells of Delight: Your New Party Hero
Picture this: you’re at a backyard gathering, and the smell of sweet smoke fills the air. Everyone is chatting, but their eyes keep drifting towards the smoker. You open the lid, revealing rows of bacon-wrapped tubes, glistening with barbecue sauce. That moment of silent, drool-filled anticipation? That’s the magic of Smoked Shotgun Shells. These are not your average appetizer. They are a bold, flavor-packed experience that turns any cook into a legend. I first made these for my husband’s poker night. The guys were so focused on eating, the card game practically stopped. That’s when I knew this recipe was a keeper.
From Pasta Tubes to Smoky Sensation
The story of this dish is a fun tale of American BBQ creativity. It doesn’t have centuries of history. Instead, it’s a brilliant modern mash-up. Someone looked at a box of manicotti pasta and saw more than just a vessel for cheese and tomato sauce. They saw a perfect, hollow tube ready to be packed with savory meat and wrapped in smoky bacon. The “shotgun” name comes from the shell-like shape, and the “delight” comes from the first unforgettable bite. It takes classic grill-out flavors—beef, sausage, bacon, and BBQ sauce—and presents them in a surprising, handheld package that’s pure fun.
Why You’ll Fall in Love With This Recipe
You will love this recipe because it is impossibly tasty and surprisingly simple. The process is almost like a fun kitchen craft project. You get to mix, stuff, and wrap. Then, the smoker does most of the hard work. The result is a perfect contrast of textures: a crispy, caramelized bacon exterior giving way to a juicy, cheesy, and warmly spiced interior. Each shell is a complete bite of happiness. They are also incredible crowd-pleasers. I’ve never brought a tray to a party without someone asking for the recipe before they’ve even finished their first one.
Perfect Occasions for These Smoky Shells
These shells are made for bringing people together. They are the star of any game day spread, from the Super Bowl to a casual Sunday football watch. They are perfect for summer cookouts, family reunions, and holiday grilling (try them for the Fourth of July!). I love making them for a big family movie night—they disappear faster than popcorn. Any event where you want to hear “Wow, you made these?” is the right event for Smoked Shotgun Shells of Delight.
Gathering Your Ingredients
Here is your shopping list for flavor town. Everything is easy to find at your local grocery store.
- 1 pound ground beef (80/20 blend is great for juiciness)
- 1 pound hot Italian sausage (casings removed)
- 1 medium onion, finely diced
- 2 cups sharp cheddar cheese, shredded
- 6 ounces cream cheese, softened
- 1 jalapeño, finely diced (remove seeds for less heat)
- 2 teaspoons Slap Ya Mama seasoning (or your favorite Cajun/creole blend)
- 2 teaspoons garlic powder
- 2 teaspoons black pepper
- 1 teaspoon red pepper flakes
- 2 boxes (8 oz each) manicotti shells (uncooked)
- 2 packages (16 oz each) regular-cut bacon
- 1 cup barbecue sauce, plus more for coating
Easy Ingredient Swaps
No problem if you need to mix things up! Here are some easy substitutions:
- Meats: Swap ground beef for ground turkey or pork. Use mild Italian sausage if you’re sensitive to spice.
- Cheese: Pepper Jack cheese adds a great kick. Colby Jack or Monterey Jack are mellower options.
- Heat Level: Omit the jalapeño and red pepper flakes for a kid-friendly version. For more fire, add a diced habanero.
- Seasoning: No Slap Ya Mama? Use any all-purpose seasoning blend like Tony Chachere’s or Lawry’s.
- Bacon: Thick-cut bacon works but may need a slightly longer cook time. Applewood or hickory-smoked bacon adds great flavor.
Crafting Your Smoked Shotgun Shells
Let’s get our hands dirty (in the best way) and build these flavor bombs.
Step 1: Create the Savory Filling
Grab your largest mixing bowl. Add the ground beef, Italian sausage (squeezed from its casing), the diced onion, and the shredded cheddar. Spoon in the soft cream cheese—it will act as a glorious binder. Sprinkle in the diced jalapeño, Slap Ya Mama, garlic powder, black pepper, and red pepper flakes. Now, roll up your sleeves and dive in! Use your hands to mix everything thoroughly. You want the bright orange cheddar, the pale creams, and the deep red meats to become one beautifully marbled, cohesive filling. The scent of garlic and spice will already have your stomach rumbling. Pro tip: Mixing with your hands is the best way to ensure everything is evenly distributed without overworking the meat.
Step 2: Gently Stuff the Shells
Take your box of uncooked manicotti shells. They are delicate, so handle with care. Scoop a handful of the meat mixture. Using your fingers, gently press the filling into the hollow tube from one end. Then, flip it and do the same from the other end, meeting in the middle. The shell should be firmly packed but not bursting. A little filling might peek out the ends, and that’s just fine. Line them up on a tray as you go. If a shell cracks a little, don’t panic. The bacon wrap will hold it all together later. Pro tip: A piping bag (or a zip-top bag with the corner cut off) can make this step less messy and even faster.
Step 3: The Bacon Blanket Wrap
Lay out a slice of bacon on your cutting board. Place one stuffed manicotti shell at one end. Carefully roll the bacon around the shell in a spiral, overlapping slightly. The goal is to cover the whole pasta tube in a single layer of bacon. Use a second slice if you need to, but try to make one work. Place the wrapped shell seam-side down on a wire rack set over a baking sheet. Repeat with all the shells. You’ll see them transform from simple pasta into promising, meaty parcels. Chef’s tip: Let the bacon sit at room temperature for 10-15 minutes before wrapping. Cold bacon is harder to stretch and can tear.
Step 4: Glaze and Get Ready to Smoke
Preheat your smoker to 250°F. Use your favorite wood—hickory or oak gives a classic strong smoke, while apple or cherry offers a sweeter, fruitier note. Now, take your extra barbecue sauce and, using a pastry brush, coat the tops of all your bacon-wrapped shells. Get a nice, even layer. This glaze will caramelize and create a sticky-sweet crust. The deep red sauce against the pink bacon is a beautiful sight. The shells are now ready for their slow, smoky transformation.
Step 5: Low and Slow Smoking
Carefully transfer the shells on their rack directly to the smoker grates. Close the lid and let the magic happen. Smoke them for 60 minutes. Then, open the smoker—be greeted by an incredible aroma—and flip each shell. Brush another coat of barbecue sauce on the new top side. Close the lid and smoke for another 60 minutes. The total cook time is about 2 hours. They are done when the bacon is fully cooked, crispy, and has a gorgeous dark mahogany color. The filling will be cooked through and juicy.
Your Recipe Timeline
Planning is key for a stress-free cooking experience.
- Preparation Time: 35 minutes (This includes mixing, stuffing, and wrapping.)
- Cooking Time: 2 hours
- Total Time: About 2 hours 35 minutes
- Servings: Makes approximately 28 shells, perfect for a crowd.
Chef’s Secret for the Best Shells
My secret is all in the cheese blend. Along with the sharp cheddar, I always add a hidden handful of grated Parmesan to the filling. It doesn’t melt the same way; instead, it adds tiny pockets of intense, salty, umami flavor that surprise you in the best way. Nobody can ever pinpoint what it is, but they always notice the depth of taste.
A Fun Fact About Manicotti
While we’re using it in a very untraditional way, manicotti pasta has a lovely history. The word “manicotti” literally means “little muffs” or “little sleeves” in Italian. Traditionally, the cooked pasta tubes are stuffed with ricotta cheese, covered in tomato sauce, and baked. Our BBQ version is a delicious American rebellion against that classic, proving that great ingredients can cross culinary borders with amazing results.
What You’ll Need to Make Them
- Large Mixing Bowl
- Smoker (or a grill set up for indirect heat)
- Wire Rack & Baking Sheet (for easy transport)
- Pastry Brush (for the BBQ sauce)
- Chopping Board & Sharp Knife
- Wood Chips or Pellets (Hickory, Apple, or Cherry are my favorites)
Storing Your Leftover Delights
If you have any leftovers (a big “if” in my house!), let them cool completely. Do not leave them at room temperature for more than two hours. Place them in a single layer in an airtight container, or wrap them tightly in aluminum foil.
They will keep in the refrigerator for 3 to 4 days. The bacon will soften in the fridge, but the flavor will still be fantastic.
To reheat, the oven or air fryer is your best friend. Preheat your oven to 350°F. Place the shells on a rack over a baking sheet and warm for 10-15 minutes until heated through and the bacon re-crisps slightly. The microwave will work in a pinch but will make the bacon soggy.
Tips and Advice for Success
- Wood Choice: Match your wood to your sauce. A sweeter, Kansas City-style BBQ sauce pairs wonderfully with milder applewood. A spicier, vinegar-based sauce can stand up to stronger hickory smoke.
- Preventing Breaks: If manicotti shells keep breaking when you stuff them, try soaking them in very warm water for 5-10 minutes to soften slightly. Dry them thoroughly before filling.
- Make Ahead: You can assemble the stuffed and wrapped shells the night before. Keep them covered on their rack in the fridge until you’re ready to smoke. Brush with sauce just before they go in.
- Don’t Rush the Smoke: Keeping a steady, low temperature (around 250°F) is crucial. It renders the bacon fat slowly for maximum crispiness without burning the outside.
Presenting Your Masterpiece
Presentation makes the party! Here are a few ideas:
- Arrange them stacked like logs on a rustic wooden cutting board. Scatter some pickled jalapeño slices and fresh herb sprigs around for color.
- Serve them upright in a wide mason jar or glass for a fun, “shotgun shell” visual effect.
- Offer small bowls of extra barbecue sauce, ranch dressing, and blue cheese dressing for dipping. Everyone loves a choice!
- For a casual backyard feel, just line them up on a big, colorful platter straight from the smoker. Let the smell do the talking.
Healthier & Creative Variations
Love the idea but want to switch it up? Try these six twists:
- Turkey Twist: Use lean ground turkey and chicken apple sausage. Swap in low-fat cream cheese and reduced-fat sharp cheddar. The smoky flavor keeps it satisfying while cutting calories.
- Breakfast Shells: Fill shells with scrambled eggs, breakfast sausage, hash browns, and cheddar. Wrap in bacon and smoke. Serve with maple syrup for dipping—the ultimate brunch showstopper.
- Pizza Lover’s Dream: Mix ground beef with pepperoni bits, mozzarella cheese, and a spoonful of pizza sauce in the filling. Wrap and smoke, then serve with a side of warm marinara for dipping.
- Buffalo Chicken Shells: Shred cooked chicken and mix with cream cheese, blue cheese crumbles, and Frank’s RedHot sauce. Wrap and smoke. Finish with a brush of buffalo sauce and a drizzle of blue cheese dressing.
- Tex-Mex Fiesta: Use a taco-seasoned meat blend, pepper jack cheese, and add a can of drained green chiles to the filling. Serve with salsa, sour cream, and guacamole on the side.
- Sweet & Smoky: Mix pork sausage with a little brown sugar and chopped apples. Use gouda cheese. Wrap in bacon and smoke with a peach or cherry wood. Glaze with a peach barbecue sauce.
Common Mistakes to Avoid
Mistake 1: Overstuffing and Breaking the Shells
It’s easy to get excited and pack too much meat into the delicate manicotti tube. This causes the dry pasta to crack and split before it even hits the smoker. A broken shell can leak filling and make wrapping with bacon difficult. To avoid this, be gentle. Use your fingers to press the filling in slowly from both ends. It should be snug but not tight. If a shell does crack, don’t toss it. Just wrap it carefully—the bacon will act like a bandage and hold it all together during cooking.
Mistake 2: Using Thin, Flimsy Bacon
The bacon is the protective jacket and flavor powerhouse. Using a very thin, cheap bacon is a recipe for disappointment. It can tear easily during wrapping and often burns or shrivels into nothing before the inside is cooked. Choose a good-quality, regular-cut bacon. It should have a decent amount of fat, as this will render slowly in the smoker, basting the shell and becoming deliciously crisp. Thick-cut bacon works too, but may require a slightly longer cooking time.
Mistake 3: Skipping the Flip and Second Glaze
Smoking for two hours without flipping is a common error. The bottom side can steam against the grate instead of smoking evenly, leaving you with one soggy side. Flipping halfway ensures all-around crispiness. The second brush of barbecue sauce is also critical. The first coat caramelizes and sets. The fresh coat after flipping adds a new layer of sticky-sweet flavor that doesn’t burn. This double-glazing technique gives you the perfect BBQ shell texture.
Mistake 4: Cooking at Too High a Temperature
Impatience leads to turning up the heat. Smoking is a low and slow game. If your smoker or grill is too hot (over 275°F), the bacon fat will render too quickly. This can cause flare-ups that burn the outside while the raw meat inside remains unsafe to eat. The bacon may also become overly dark and bitter. Aim for a steady 250°F. This gives the fat time to melt slowly, the smoke time to penetrate, and results in a perfectly cooked, crispy, and deeply flavorful shell.
Your Smoked Shotgun Shell Questions, Answered
Can I make these in the oven instead of a smoker?
Absolutely, you can! Preheat your oven to 275°F. Prepare the shells as directed and place them on a wire rack over a baking sheet lined with foil (for easy cleanup). Bake for about 2 hours, flipping and brushing with more sauce halfway through. The bacon will get crispy, and they will be delicious. To add a hint of smoke flavor without a smoker, you can add a half teaspoon of liquid smoke to your barbecue sauce glaze. While not exactly the same, it will give a similar smoky note.
Can I use a different pasta shape?
The manicotti shell is ideal because it’s a large, hollow tube perfect for stuffing. If you can’t find it, jumbo pasta shells (conchiglioni) are the closest substitute. They are smaller and shaped like seashells, so you’ll get more pieces, and the wrapping will be trickier. You could also use cannelloni tubes, which are very similar to manicotti. Avoid using stuffed pasta like ravioli or tortellini, as they are already filled and will not work for this recipe’s method.
How do I know when they are fully cooked?
The best indicator is the bacon. It should be fully cooked, crisp, and have a rich, dark color. There should be no soft, rubbery, or translucent pink spots on the bacon. The internal temperature of the meat filling should reach a safe 160°F when checked with an instant-read thermometer inserted into the center of a shell. If the bacon looks perfect but you’re unsure, just take one shell out, cut it open, and check that the meat is no longer pink and is piping hot all the way through.
What’s the best way to serve these at a party?
These are fantastic finger food, so keep it simple. Provide plenty of napkins! I like to serve them on a large platter straight from the smoker while they’re still warm. Have small bowls of extra barbecue sauce, ranch dressing, or even a cool blue cheese dip on the side for those who want it. Toothpicks can be helpful for serving, but they aren’t necessary. Just let people know the shells might be a little hot inside when they first bite into them.
Can I prepare these ahead of time?
Yes, you can do most of the work ahead. You can fully assemble the stuffed and bacon-wrapped shells. Place them on their baking sheet with the wire rack, cover tightly with plastic wrap, and refrigerate for up to 24 hours. When you’re ready to cook, take them out of the fridge, brush with the first coat of sauce, and let them sit at room temperature for about 20-30 minutes while your smoker preheats. This helps them cook more evenly from the start.
How many does this recipe really serve?
The recipe makes about 28 shells. For a big party where these are one of many appetizers, plan for people to eat 2-3 shells each. If you’re serving them as the main appetizer or part of a smaller meal, like a family dinner with sides, plan for 4-5 shells per person. They are rich and filling! I always recommend making the full batch. They reheat well, and any leftovers make for an incredible next-day snack—if you’re lucky enough to have any.
My bacon isn’t getting crispy. What did I do wrong?
There are a couple of likely culprits. First, check your temperature. Smoking below 225°F might not be hot enough to fully render the fat and crisp the bacon. Make sure you’re at a steady 250°F. Second, you might have wrapped the bacon too tightly, with too much overlap. The bacon needs space for the fat to render out. If slices are layered too thickly, they steam instead of crisp. Finally, make sure you are using a wire rack so air can circulate all around the shell, not a solid pan where they sit in their own grease.
Are these shells very spicy?
The recipe as written has a moderate kick from the hot Italian sausage, jalapeño, and red pepper flakes. However, you have full control! To make them mild, use mild Italian sausage, omit the jalapeño and red pepper flakes entirely, and use a sweet barbecue sauce. The Slap Ya Mama seasoning adds flavor more than intense heat. For a truly fiery version, keep the hot sausage, add a second jalapeño with seeds, and use a spicy barbecue sauce or even a habanero hot sauce mixed into the glaze.
Can I freeze Smoked Shotgun Shells?
You can freeze them after they are cooked and cooled. Place them in a single layer on a baking sheet to “flash freeze” for an hour, then transfer to a freezer-safe bag or container. They will keep for up to 2 months. To reheat, do not thaw. Place the frozen shells on a rack over a baking sheet in a preheated 350°F oven for 20-25 minutes, until heated through and the bacon is crispy again. The texture of the pasta may soften slightly, but the flavor will still be great.
What sides go well with this dish?
Since these are rich and smoky, pair them with fresh, cool, or creamy sides to balance the meal. A simple, crisp coleslaw is a classic and perfect choice. Creamy potato salad, baked beans, or a fresh corn and black bean salad are also fantastic. For a lighter option, a big garden salad with a tangy vinaigrette works wonders. Don’t forget the cornbread or dinner rolls to soak up any extra flavor!
Go Forth and Smoke!
There you have it—your complete guide to creating the ultimate party snack. Smoked Shotgun Shells of Delight are more than just food; they are a conversation starter, a memory maker, and a surefire way to become the most popular cook in your friend group. They might seem involved, but each step is simple and honestly, kind of fun. So fire up that smoker, get your hands messy, and get ready for the compliments to roll in. Trust me, once that smoky, savory, cheesy aroma fills your backyard, you’ll know it was all worth it. Happy smoking!
Strawberry Cream Cheesecake
Ingredients
Equipment
Method
- In a large mixing bowl, combine the ground beef, Italian sausage, diced onion, shredded cheddar, softened cream cheese, diced jalapeño, Slap Ya Mama seasoning, garlic powder, black pepper, and red pepper flakes. Mix thoroughly with hands.
- Using uncooked manicotti shells, scoop a handful of the meat mixture and press it gently into the shell from both ends, meeting in the middle.
- Lay a slice of bacon on a cutting board, place one stuffed manicotti shell at one end, and roll the bacon around the shell. Place seam-side down on a wire rack.
- Preheat the smoker to 250°F and coat the tops of the bacon-wrapped shells with barbecue sauce using a pastry brush.
- Transfer the shells to the smoker and smoke for 60 minutes. Flip the shells, coat with more barbecue sauce, and smoke for another 60 minutes until bacon is crispy and filling is cooked through.