Easy Smoked Shotgun Shells

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Smoked shotgun shells have taken the BBQ world by storm, and for good reason. Manicotti pasta stuffed with seasoned ground beef, Italian sausage, and cream cheese, wrapped in crispy bacon, and finished with a sweet BBQ glaze—what’s not to love? These have become my most-requested appetizers at cookouts, tailgates, and game-day parties. They’re surprisingly simple to make and always disappear within minutes. Kids and adults alike can’t get enough of them.

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Easy Shotgun Shells

If you’re looking for the perfect appetizer for your next cookout, tailgate, or party, smoked shotgun shells are it. Tender manicotti tubes packed with ground beef, Italian sausage, and melted cheese, wrapped in bacon, and smoked until crispy. A quick brush of BBQ sauce at the end gives them that irresistible sweet and tangy finish. They’re simple to put together but taste like you spent hours in the kitchen. Trust me—make a double batch because these never last long.

What You’ll Need

• Jumbo pasta shells – Choose shells that are uniform in size without cracks or breaks, ensuring they hold filling properly and cook evenly throughout the smoking process.
• Ground beef – Select 80/20 ground beef for the perfect fat content, which keeps the filling moist during the extended smoke and adds rich, beefy flavor.
• Italian sausage
• Cream cheese
• Bacon – Regular-cut works best here rather than thick-cut, allowing it to crisp up properly while the filling cooks through without burning.

• Shredded mozzarella cheese
• Shredded cheddar cheese
• Italian seasoning
• Garlic powder
• Black pepper
• Red pepper flakes
• BBQ sauce
• Honey
• Apple cider vinegar

Ingredient Substitutes

All ground beef or all Italian sausage – You can use a full pound of either meat instead of splitting them, though the combination provides the best flavor balance between the richness of beef and the herbs in sausage.

Goat cheese or ricotta for cream cheese – Both bring a tangier profile and lighter texture to the filling, though the consistency will be slightly less creamy and more crumbly after smoking.

Turkey bacon for regular bacon – This reduces fat and calories significantly while still providing the wrapped presentation, but expect less crispiness and a milder smoky flavor overall.

Gluten-free jumbo shells – Several quality brands make these from rice or corn flour, working perfectly in this recipe while maintaining excellent structure throughout the smoking process.

How to Make Smoked Shotgun Shells

Step 1: Prepare the Pasta Shells

Bring a large pot of salted water to a rolling boil and add the jumbo shells. Cook them for 9-10 minutes until they reach al dente texture—firm enough to handle but tender enough to eat after smoking. Drain immediately and rinse under cold water to stop the cooking process. Spread them out on a clean kitchen towel to dry completely, as excess moisture will prevent the bacon from crisping properly during the smoke.

Step 2: Make and Stuff the Filling

Combine the raw ground beef and Italian sausage with room-temperature cream cheese in a large bowl, breaking up any chunks with your hands. Add both shredded cheeses along with Italian seasoning, garlic powder, black pepper, and optional red pepper flakes.

Mix thoroughly until everything is evenly distributed and the meats are well combined. Pack each dried pasta shell completely with the meat mixture using a small spoon or your fingers, filling them generously and eliminating air pockets.

Step 3: Wrap and Prepare for Smoking

Take one bacon slice and wrap it around each stuffed shell in a spiral pattern, covering as much of the pasta as possible. The bacon should overlap slightly and fit snugly. Use toothpicks to secure the ends if needed. Then covered in the rub. Set your smoker to 225°F and allow it to come to temperature with your wood chips loaded.

Step 4: Smoke the Shells

Place the wrapped shells directly on the grate, leaving space between them for smoke circulation. Let them smoke undisturbed for 90 minutes, allowing the bacon to render and the filling to cook through while absorbing wood flavor. The shells should start to look golden and the bacon will begin crisping.

Step 5: Glaze and Finish

Mix the BBQ sauce, honey, and apple cider vinegar in a small bowl until smooth. After the initial 90-minute smoke, brush this glaze generously over each shell, coating all the bacon surfaces. Continue smoking for another 30 minutes until the bacon turns crispy and golden brown.

Check the internal temperature with an instant-read thermometer—it should register 165°F in the center of the filling. Remove from the smoker and let the shells rest for 5 minutes before carefully removing any toothpicks and serving while warm.

How To Store Leftovers and Reheat

Allow leftover shotgun shells to cool to room temperature before transferring them to an airtight container. Store in the refrigerator for up to 4 days. For best results when reheating, place the shells on a baking sheet and warm them in a 350°F oven for 12-15 minutes, until heated through and the bacon crisps back up.

You can also reheat individual shells in an air fryer at 375°F for 5-7 minutes. Avoid microwaving if possible, as it makes the bacon rubbery and the pasta soggy. These shells freeze well for up to 2 months—thaw overnight in the refrigerator before reheating.

My Favorite Wood Chips for Shotgun Shells

Apple wood delivers a mild, slightly sweet smoke that complements the Italian sausage without overpowering the cheese and bacon, making it my top choice for this recipe.

Cherry wood adds a beautiful color and fruity undertone that pairs wonderfully with the BBQ glaze. Hickory imparts a stronger, more traditional BBQ flavor that pairs well with spicy Italian sausage.

Pecan offers a nutty, medium-smoke flavor that pairs well with all the rich ingredients. Avoid mesquite as it’s too intense and can make the delicate pasta taste bitter during the long cook time.

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More Appetizers to Serve with Shotgun Shells

• 🌶️ Grilled Jalapeno Poppers
• 🧀 Smoked Queso
• 🧅 Traeger Smoked Onion Bombs
• 🧆 Game Day Crunchy Meatballs
• 🍔 Super Bowl Sliders

Smoke On!

Charlie

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