Smoked Shotgun Shells Bacon

These loaded bacon-wrapped beauties have become the star of every gathering I host. Picture this: tender manicotti shells packed with seasoned ground beef and Italian sausage, wrapped in crispy bacon, and kissed with smoky barbecue flavor. I discovered this recipe during a weekend barbecue competition prep, and now friends literally text me asking when I'm making them next. The combination of pasta, meat, cheese, and bacon creates an irresistible appetizer that's substantial enough to satisfy even the heartiest appetites.

The first time I served these at a family reunion, my uncle declared them better than any restaurant appetizer he'd ever had. Now they're requested at every holiday gathering, and I've learned to double the batch because they disappear fast.

Ingredients

• 2 boxes (8 ounces each) manicotti shells: Choose quality pasta that won't break during stuffing
• 1½ pounds ground beef: I prefer 80/20 for the right fat content and flavor
• 1 pound hot Italian sausage: The spice level balances perfectly with the other ingredients
• 1 medium onion, finely diced: Sweet onions work beautifully for mellowing the heat
• 2 cups sharp cheddar cheese: Sharp cheddar melts better and adds tang
• 6 ounces cream cheese: This creates the creamy binding that holds everything together
• 1 jalapeño, finely diced: Remove seeds for less heat or keep them for fire
• 2 teaspoons Slap Ya Mama seasoning: Substitute with Cajun seasoning if needed
• 2 teaspoons garlic powder: Fresh garlic burns too easily in the smoker
• 2 teaspoons black pepper: Freshly ground makes a noticeable difference
• 1 teaspoon red pepper flakes: Adjust to your heat preference
• ⅓ cup barbecue sauce: Choose a thick sauce that won't make the filling soggy
• 2 packages (16 ounces each) bacon: Buy extra because some pieces will break
• Additional barbecue sauce for coating: I like a sweeter sauce for the exterior

Step-by-Step Instructions

Prepare Your Smoker:

Fire up your smoker to 250 degrees Fahrenheit. This lower temperature ensures the pasta cooks through while the bacon gets perfectly crispy without burning. I use hickory or apple wood for the best flavor combination.

Create the Filling Mixture:

Combine all ingredients except bacon and extra barbecue sauce in a large mixing bowl. The key here is not to overcook the meat first since it will cook beautifully in the smoker. Mix gently with your hands to distribute everything evenly without overworking the meat.

Stuff the Shells:

Here's where patience pays off. Gently stuff the uncooked manicotti shells from both ends, using a small spoon or your fingers to push the mixture deep inside. Pack firmly but don't force it, or you'll crack the pasta. Make sure there are no air pockets, as these can cause uneven cooking.

Wrap with Bacon:

Wrap each stuffed shell with bacon slices, covering the ends completely. Some shells need two pieces of bacon depending on their length. The bacon should overlap slightly to stay secure during smoking. I learned to secure with toothpicks if needed.

Apply the Glaze:

Brush additional barbecue sauce over both sides of each wrapped shell. This creates that beautiful caramelized exterior we're after. Place them on a rimmed baking sheet while you finish the remaining shells.

Smoke to Perfection:

Smoke for 60 minutes, then carefully flip each shell over. Brush with more barbecue sauce and continue smoking for another 60 minutes. The bacon should be golden brown and crispy, and the internal temperature should reach 160 degrees Fahrenheit.

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The cream cheese in this recipe is what transforms ordinary stuffed shells into something extraordinary. It creates that perfect creamy texture that binds all the flavors together while keeping everything moist during the long smoking process. I remember the first batch I made without it and the filling was dry and crumbly.

Storage and Reheating

Store leftovers in the refrigerator for up to 4 days in an airtight container. Reheat in a 350 degree oven for 10 to 15 minutes until heated through. The microwave works in a pinch, but you'll lose that crispy bacon texture that makes these so special. For best results, I recommend reheating on a wire rack over a baking sheet to maintain crispiness.

Ingredient Substitutions

Ground turkey can replace the beef for a lighter version, though you'll want to add an extra tablespoon of barbecue sauce to compensate for the lower fat content. Mild Italian sausage works if you prefer less heat, and you can substitute the jalapeños with bell peppers for a completely mild version. Mozzarella cheese melts beautifully as an alternative to cheddar, creating more of an Italian flavor profile.

Serving Suggestions

These make an outstanding appetizer served with ranch dressing or extra barbecue sauce for dipping. I like to arrange them on a wooden cutting board with some pickled vegetables and crackers for a complete spread. They're substantial enough to serve as a main course alongside coleslaw and baked beans for a full barbecue meal. Cut them in half diagonally for easier eating at parties.

Smoking Tips and Techniques

The key to perfect shotgun shells lies in maintaining consistent temperature and not rushing the process. I've found that placing a water pan in the smoker helps maintain moisture and prevents the pasta from drying out. Rotate the shells halfway through cooking for even browning, and don't open the smoker too frequently as this drops the temperature and extends cooking time.

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Frequently Asked Questions About Recipes

→ Do I need to cook the meat before stuffing the shells?

No, the beef and sausage go in raw. They will cook fully during the smoking process.

→ Can I prepare these ahead of time?

Yes, assemble a day ahead and refrigerate. Brush with barbecue sauce just before smoking.

→ What type of smoker works best?

Any smoker is fine, as long as you maintain a steady 250°F for even cooking and crisp bacon.

→ Can I use different cheeses inside?

Absolutely. Try pepper jack, mozzarella, or a cheese blend for different flavor profiles.

→ How can I prevent the shells from breaking?

Stuff gently from both ends and avoid overfilling. Handle the pasta with care to prevent cracks.

→ What’s the best way to reheat leftovers?

Reheat in a 350°F oven for 10–15 minutes to keep the bacon crisp. Avoid microwaving if possible.