Smoked Shotgun Shells Bacon

Featured in: Perfect Bites for Every Occasion

Big, cheesy manicotti shells are filled with a blend of seasoned ground beef, hot Italian sausage, sharp cheddar, and cream cheese, then wrapped in smoky bacon. Basted with tangy barbecue sauce and slowly smoked until the bacon is crisp, each stuffed shell bursts with juicy, spiced flavor. This homestyle dish pairs classic pasta comfort with bold barbecue taste and is perfect for backyard gatherings or sharing with friends.

A woman in a chef's hat smiles for the camera.
By Sana Rose
Updated on Wed, 25 Jun 2025 14:49:40 GMT
A plate of smoked bacon wrapped around a sausage, with cheese in the middle. Pin it
A plate of smoked bacon wrapped around a sausage, with cheese in the middle. | recipebyme.com

Smoked shotgun shells are my go-to for backyard gatherings whenever I want something smoky savory and outrageously satisfying. Pasta tubes are packed with a cheesy spicy meat mixture then they get wrapped in bacon and kissed with barbecue flavor before a slow smoke brings everything together. These little bundles are a crowd favorite every time and you will find everyone sneaking extra from the tray.

My family cannot get enough of these They have become our signature cookout treat and even the leftovers get devoured cold from the fridge

Ingredients

  • Manicotti shells: look for unbroken tubes since they are easier to stuff
  • Ground beef: use 80 percent lean for moisture and extra flavor
  • Hot Italian sausage: brings big bold taste and juiciness
  • Onion: finely diced makes the filling more aromatic and tender
  • Sharp cheddar cheese: gives a sharp bite and melts beautifully try to buy it fresh and shred it yourself
  • Cream cheese: adds richness and binds everything together choose the best quality for smoothness
  • Jalapeno: brings subtle heat remove seeds if you prefer less spice
  • Slap Ya Mama seasoning: for a Creole punch you can swap with your favorite Cajun blend
  • Garlic powder: infuses the whole mix with sweet garlicky notes buy a fresh jar for best flavor
  • Black pepper: for warmth and balance in every bite use freshly cracked if possible
  • Red pepper flakes: for extra heat add or reduce based on preference
  • Barbecue sauce: helps the filling stay moist and adds tang look for a smoky robust style
  • Bacon: the star of the show look for thick cut so it crisps slowly and holds in the filling
  • Extra barbecue sauce: paints the shells before and during smoking for deep color and flavor

Instructions

Preheat the Smoker:
Set your smoker to 250 degrees Fahrenheit and allow it to preheat for at least 15 minutes A hot stable temperature is key for rendering the bacon slowly and infusing maximum smoke flavor
Mix the Filling:
In a very large bowl add ground beef Italian sausage finely diced onion sharp cheddar cream cheese diced jalapeno Slap Ya Mama seasoning garlic powder black pepper red pepper flakes and the barbecue sauce Use clean hands to blend until completely uniform and smooth Every bite should have a balance of meat spice and creamy cheese
Stuff the Shells:
Take uncooked manicotti shells and gently fill them from both ends pressing the filling inside with your fingers Pack tightly so there are no gaps or air pockets If the shells crack just patch gently with a small piece of bacon later
Wrap in Bacon:
Take one to two strips of bacon per shell and wrap tightly so the ends are covered and none of the filling peeks out Slightly overlap the bacon as you wrap to avoid gaps where cheese might bubble out If your bacon is short use a second piece to finish covering
Glaze with Barbecue Sauce:
Use a pastry brush to coat each bacon-wrapped shell with a generous layer of barbecue sauce on all sides Set them on a wire rack over a baking sheet to catch any drips while you finish the batch
Smoke Low and Slow:
Transfer the prepared shells to the smoker making sure to leave space between for smoke circulation After 60 minutes use tongs to flip each shell carefully then brush with more barbecue sauce Close the lid and smoke for another hour or until the bacon looks deep brown and crisp The filling should feel firm to the touch
Serve Hot:
Remove the shells from the smoker and let rest for five minutes before serving This allows the fillings to set a bit Cut into pieces or serve whole with extra barbecue sauce on the side
A plate of smoked bacon wrapped around a sausage, ready to be cooked.
A plate of smoked bacon wrapped around a sausage, ready to be cooked. | recipebyme.com

My favorite ingredient is the jalapeno It is just enough heat to keep things interesting and I love how my kids always try guessing what gives that pleasant little kick This recipe brings us together whenever we get the smoker going even if friends are just coming by for a quick hello

Storage Tips

Store leftovers tightly wrapped in foil or an airtight container They will keep for up to four days in the fridge For longer storage these freeze well Just wrap each shell individually and thaw in the fridge overnight before reheating in a low oven or air fryer

Ingredient Substitutions

You can use any ground meat here Pork turkey or chicken all work For less heat try using sweet Italian sausage instead of hot Monterey jack or mozzarella can stand in for cheddar in a pinch If fresh jalapeno is not available use canned green chilies

Serving Suggestions

Serve hot as a main dish with a side of slaw or potato salad At parties I cut each shell in bite-size rounds and serve with toothpicks and a dipping bowl of barbecue sauce The smoky flavor is also excellent with baked beans or grilled corn

Cultural Roots

This recipe blends southern barbecue with a playful twist from Italian American favorites The name shotgun shells comes from the pasta tube shape and classic backyard smoker culture These have become popular on the barbecue circuit in recent years for both their look and craveability

A plate of smoked bacon with green onions on top.
A plate of smoked bacon with green onions on top. | recipebyme.com

The best shotgun shells are smoky cheesy and perfectly crisp. Make a double batch because these disappear fast every single time.

Recipe FAQs

→ How do I prevent manicotti shells from breaking while stuffing?

Use gentle pressure and fill from both ends, ensuring the meat mixture is evenly packed but not forced, to avoid cracking.

→ Can I substitute another meat for hot Italian sausage?

Yes, use mild Italian sausage, ground pork, or chicken sausage for less heat, adjusting seasonings as needed.

→ Is it necessary to precook the manicotti shells?

No, stuffing uncooked shells lets them soften while smoking and absorb flavorful juices from the filling.

→ How crispy should the bacon be when finished?

The bacon should be fully cooked and crisped on the outside, but not burned. Smoking time can be adjusted to taste.

→ Can this dish be made in an oven instead of a smoker?

Yes, bake at 375°F until the bacon is golden and the filling is cooked through, flipping halfway and basting with barbecue sauce.

Smoked Shotgun Shells Bacon

Hearty stuffed shells wrapped in bacon, filled with spiced beef, sausage, and creamy cheese.

Prep Time
30 min
Cook Time
120 min
Total Time
150 min
By Sana: Rose


Skill Level: Medium

Cuisine: American

Yield: 8 Servings (16 shotgun shells)

Dietary Categories: ~

Ingredients

→ Pasta

01 16 ounces manicotti shells

→ Meat Filling

02 1.5 pounds ground beef
03 1 pound hot Italian sausage
04 1 medium onion, finely diced
05 2 cups shredded sharp cheddar cheese
06 6 ounces cream cheese, softened
07 1 jalapeño, finely diced

→ Seasonings

08 2 teaspoons Slap Ya Mama seasoning
09 2 teaspoons garlic powder
10 2 teaspoons ground black pepper
11 1 teaspoon red pepper flakes

→ Other

12 1/3 cup barbecue sauce
13 32 ounces sliced bacon
14 additional barbecue sauce for basting

Steps

Step 01

Set smoker to 250°F and allow to preheat until temperature is consistent.

Step 02

In a large mixing bowl, add ground beef, hot Italian sausage, diced onion, shredded cheddar cheese, cream cheese, diced jalapeño, Slap Ya Mama seasoning, garlic powder, black pepper, red pepper flakes, and 1/3 cup barbecue sauce. Blend thoroughly with clean hands or a spatula until the mixture is uniformly combined.

Step 03

Gently fill uncooked manicotti shells with the prepared meat mixture from both ends, pressing to ensure shells are fully and evenly packed without any air pockets.

Step 04

Encase each stuffed shell completely in sliced bacon, overlapping ends and using two pieces if needed to ensure full coverage.

Step 05

With a pastry brush, apply a generous coating of additional barbecue sauce to all sides of each bacon-wrapped shell. Set aside on a baking sheet as you work.

Step 06

Transfer shells to the preheated smoker. Smoke for 60 minutes, then carefully flip each shell. Baste again with barbecue sauce and continue smoking for another 60 minutes, or until bacon is crisp and rendered.

Step 07

Remove shells from the smoker. Serve immediately while hot.

Notes

  1. Allow bacon-wrapped shells to rest for 5 minutes after smoking for optimal texture and flavor.

Required Equipment

  • Smoker
  • Large mixing bowl
  • Pastry brush
  • Baking sheet

Allergen Information

Check each ingredient for potential allergens and consult a healthcare professional if needed.
  • Contains milk, cheese, and possible gluten from pasta.

Nutritional Info (per serving)

This data is provided as a guide and doesn't replace medical advice.
  • Calories: 730
  • Fats: 48 g
  • Carbohydrates: 32 g
  • Proteins: 38 g