Shotgun Shells Bacon Delight

There is nothing quite like the crowd-stopping combination of smoky bacon, cheesy filling, spicy sausage, and a sweet-hot glaze all wrapped up in a golden shell. Shotgun Shells Bacon brings the thrill of barbecue together with the comfort of stuffed pasta — the sort of dish you make for backyard gatherings and see disappear before you can even blink.

My family eats these almost as fast as I can make them and neighbors always ask for the recipe. The very first time I brought a tray of Shotgun Shells Bacon to a party, they barely lasted ten minutes.

Ingredients

• Manicotti shells: Provide structure and soak up flavor from the filling. Choose ones that are unbroken and uniform in size
• Ground beef: Delivers a juicy hearty texture. Go for an 80 percent lean blend for the best balance
• Hot Italian sausage: Spices things up and keeps the filling tender. Ask your butcher for good quality links and remove the casing
• Onion: Adds just the right backbone of sweetness. Look for one that feels heavy and firm
• Sharp cheddar cheese: Gives blend and richness. Shred it yourself for better melting
• Cream cheese: Ensures the filling stays moist and creamy
• Jalapeño: Brings a subtle kick. Choose a bright green pepper with no soft spots
• Slap Ya Mama seasoning: Enhances every element with Cajun spice. Looking for quality blends makes all the difference
• Garlic powder and ground black pepper: Provide warmth and depth. Freshly ground pepper works best here
• Red pepper flakes: Introduce background heat
• Barbecue sauce: Adds tangy sweetness and helps the bacon glaze up
• Bacon: Wraps everything in smoky goodness. Thick-cut but still pliable bacon works perfectly
• Extra barbecue sauce for basting: Means that sticky glossy finish

Instructions

Set Up the Smoker:

Heat your smoker to 250 degrees F and let it preheat until the temperature is steady. This gives the shells a chance to cook slowly and lets the bacon render properly.

Mix the Filling:

In a big bowl combine ground beef, hot Italian sausage, finely diced onion, shredded cheddar, softened cream cheese, minced jalapeño, Slap Ya Mama seasoning, garlic powder, black pepper, red pepper flakes, and a portion of barbecue sauce. Mix it all together by hand or with a spatula until the texture is even throughout and everything looks well distributed.

Stuff the Manicotti:

Take uncooked manicotti shells and carefully fill them from both ends using your fingers or a piping bag, packing the meat mixture tightly to avoid gaps or air pockets inside.

Wrap with Bacon:

Cover each stuffed shell completely in bacon, making sure the strips overlap slightly and cover both ends. Use a second piece as needed so that all pasta is tucked in and sealed.

Glaze with Barbecue Sauce:

Brush the outer bacon with a thick coat of extra barbecue sauce. Set each shell on a lined baking sheet as you go to make transport easier.

Smoke the Shells:

Lay the bacon-wrapped shells onto the smoker rack with a bit of space between each. Smoke for one hour, then turn each shell over to crisp evenly. Brush with more barbecue sauce and continue smoking for another hour or until the bacon is browned and crisp at the edges and the meat registers at least 165 degrees F inside.

Serve Hot:

Remove the finished shotgun shells from the smoker and set them on a platter. Serve immediately for the best ooey-gooey texture.

I cannot resist a crisp-edged bacon wrap and find it turns any event into a celebration. My son once requested these for his birthday instead of cake. The combination of smoky bacon with gooey cheese inside is what keeps people coming back for seconds.

Storage Tips

Leftovers refrigerate well in an airtight container for up to three days. Reheat in an oven or toaster oven to keep the bacon crispy. For longer storage, assemble but do not smoke, and freeze tightly wrapped shells. When ready to serve, thaw overnight then smoke as usual.

Ingredient Substitutions

Not a fan of spicy sausage Swap for sweet Italian sausage or even seasoned ground turkey. Monterey Jack or pepper jack cheeses trade easily for sharp cheddar for a milder or extra zesty filling. Try different barbecue sauces to play with sweet or smoky undertones depending on your crowd.

Serving Suggestions

Pile these shells on a platter scattered with chopped green onions and extra sauce for dipping. These make an unforgettable main course but also work as appetizers for large backyard gatherings or potlucks. Serve next to crisp coleslaw, baked beans, and a big bowl of pickles for a true barbecue feast.

Cultural and Seasonal Adaptations

This recipe takes a page from Italian-American stuffed pasta and cranks it up with Southern barbecue flair. In warm months enjoy on the patio with fresh summer salads. Come winter make them indoors using the oven at 300 degrees F on a rack for a smoky effect.

Let the shells rest for a few minutes before slicing so the filling stays put. Every time I make this recipe, someone asks for it!

Recipe FAQs

→ How do you prevent manicotti shells from breaking when stuffing?

Stuff the shells gently using a small spoon or piping bag, ensuring the filling is evenly packed to minimize pressure and avoid breaking.

→ Can I use a grill instead of a smoker?

Yes, a grill set for indirect heat can be used. Add wood chips for smoke and monitor the temperature to stay around 250°F.

→ What cheese works best for this dish?

Sharp cheddar and cream cheese blend well, adding both tanginess and creaminess to complement the savory meat and bacon.

→ Is there a way to make these less spicy?

Omit or reduce jalapeño, hot sausage, and red pepper flakes for a milder version without sacrificing flavor.

→ How do you keep bacon crispy during smoking?

Use thin-cut bacon, baste regularly, and ensure proper heat circulation for a crisp, evenly rendered finish.

→ Can the shells be prepared in advance?

Yes, assemble and refrigerate for a few hours before smoking. Bring to room temperature before starting the process.