There’s something magical about combining two comfort food classics – stuffed pasta and crispy bacon – into one show-stopping dish. When I first discovered smoked shotgun shells, I knew I’d found my new go-to recipe for impressing guests and satisfying serious appetites. These bacon-wrapped, cheese-filled manicotti shells have become the star of every barbecue gathering at my house.
The name “shotgun shells” comes from their resemblance to ammunition casings, but don’t let that fool you – these are pure comfort food gold. What started as a creative twist on traditional stuffed shells has evolved into a smoky, indulgent masterpiece that bridges the gap between appetizer and main course.
Why You’ll Fall in Love with This Recipe
Bold Flavors That Pack a Punch
This recipe delivers an incredible flavor combination that hits all the right notes. The smoky bacon exterior creates a perfect contrast to the creamy, spicy filling inside. Meanwhile, the sharp cheddar and cream cheese blend creates a rich, satisfying base that balances beautifully with the heat from jalapeños and Italian sausage.
Perfect for Entertaining
These shotgun shells are conversation starters that never fail to impress. They look incredibly sophisticated on the plate, yet they’re surprisingly approachable to make. Additionally, they serve double duty as both appetizer and main course, making meal planning effortless for your next gathering.
Customizable Heat Level
The beauty of this recipe lies in its adaptability. You can easily adjust the spice level by modifying the jalapeño quantity or choosing mild Italian sausage instead of hot. Furthermore, the Slap Ya Mama seasoning adds that perfect Louisiana kick without overwhelming the other flavors.
Essential Ingredients
Prep Time: 30 Minutes | Cook Time: 120 Minutes | Total Time: 150 Minutes
Serves: 8 people (16 stuffed shells) | Difficulty: Intermediate | Cuisine: American
Main Components
Pasta Foundation:
- 450g manicotti shells (uncooked)
Hearty Meat Filling:
- 680g ground beef
- 450g hot Italian sausage
- 1 medium onion, finely diced
- 200g sharp cheddar cheese, shredded
- 170g cream cheese, softened
- 1 jalapeño, finely diced
Flavor Enhancers:
- 2 tsp Slap Ya Mama seasoning
- 2 tsp garlic powder
- 2 tsp ground black pepper
- 1 tsp red pepper flakes
Finishing Touches:
- 80ml barbecue sauce (plus extra for basting)
- 900g bacon slices
Serving Suggestions
These shotgun shells pair beautifully with coleslaw, grilled corn on the cob, or a fresh garden salad. For beverages, consider serving with cold beer, sweet tea, or a robust red wine that can stand up to the smoky flavors.
Step-by-Step Instructions
Preparation Phase
Step 1: Fire Up Your Smoker Begin by setting your smoker to 120°C (248°F). Allow adequate time for the temperature to stabilize completely before adding your food. This ensures even cooking throughout the smoking process.
Step 2: Create the Filling In a large mixing bowl, combine ground beef, hot Italian sausage, and diced onion. Next, add the shredded cheddar cheese, softened cream cheese, and finely diced jalapeño. Season with Slap Ya Mama seasoning, garlic powder, black pepper, and red pepper flakes. Finally, incorporate 80ml of barbecue sauce and mix thoroughly until the filling achieves a uniform consistency.
Assembly Process
Step 3: Stuff the Shells Working with uncooked manicotti shells, carefully fill each shell from both ends using the prepared meat mixture. Gently compact the filling to eliminate air pockets while ensuring even distribution throughout each shell. This technique prevents gaps that could lead to uneven cooking.
Step 4: Wrap with Bacon Completely encase each stuffed shell with bacon slices, ensuring no pasta remains exposed. Use overlapping techniques to achieve full coverage, adding extra bacon strips if necessary. The bacon not only adds flavor but also protects the pasta during the smoking process.
Smoking Process
Step 5: Final Preparation Using a pastry brush, generously coat each bacon-wrapped shell with additional barbecue sauce. Arrange the prepared shells on a baking sheet, leaving space between each piece for proper air circulation.
Step 6: First Smoking Phase Transfer the shells to your preheated smoker and smoke for 60 minutes. The low temperature allows the flavors to develop while the bacon begins to render its fat.
Step 7: Turn and Continue Carefully turn each shell to ensure even cooking on all sides. Baste again with barbecue sauce to maintain moisture and build that beautiful glaze. Continue smoking for another 60 minutes until the bacon becomes crispy and fully rendered.
Step 8: Final Check and Serve Remove the shells when the bacon reaches your desired level of crispiness. Serve immediately while hot to enjoy the optimal texture contrast between the crispy exterior and creamy interior.
Creative Serving Ideas
Presentation Options
Arrange the shotgun shells on a wooden cutting board with small bowls of extra barbecue sauce and ranch dressing for dipping. Garnish with fresh chopped green onions or cilantro for a pop of color and freshness.
Portion Considerations
For appetizer portions, plan on 1-2 shells per person. However, if serving as a main course, 2-3 shells per person provides a satisfying meal, especially when paired with lighter sides.
Recipe Variations to Try
Cheese Lovers’ Version
Replace the sharp cheddar with a blend of pepper jack and smoked gouda for extra complexity. Additionally, consider adding a layer of mozzarella on top during the final 15 minutes of smoking for a beautifully melted finish.
Breakfast-Inspired Twist
Substitute the Italian sausage with breakfast sausage and add scrambled eggs to the filling. This variation makes an excellent brunch dish that’s sure to impress your guests.
Vegetarian Alternative
Create a meat-free version using a mixture of ricotta, spinach, sun-dried tomatoes, and mushrooms. Season with Italian herbs and garlic for a delicious plant-based option that still delivers incredible flavor.
Spice Level Adjustments
For milder tastes, use mild Italian sausage and reduce the jalapeño quantity. Conversely, heat enthusiasts can add habanero peppers or increase the red pepper flakes for extra kick.
Make-Ahead Tips
Preparation Timeline
These shotgun shells can be assembled up to 24 hours in advance. Simply wrap the completed shells tightly in plastic wrap and refrigerate until ready to smoke. This actually improves the flavors as the ingredients meld together overnight.
Freezing Instructions
For longer storage, individually wrap assembled shells in aluminum foil and freeze for up to three months. When ready to cook, thaw completely in the refrigerator before smoking. Add an extra 15-20 minutes to the cooking time if starting from chilled.
Batch Cooking Strategy
Consider doubling the recipe and freezing half for future meals. Label each package with cooking instructions for easy preparation later.
Important Notes
Cooking Temperature Considerations
Using uncooked manicotti shells is crucial for this recipe’s success. The pasta absorbs moisture from the filling during the smoking process, resulting in perfectly tender shells without the need for pre-boiling.
Bacon Selection Tips
Choose thick-cut bacon for the best results, as thin bacon may become overly crispy before the filling reaches proper temperature. Additionally, ensure the bacon covers the entire shell to prevent any pasta from drying out during smoking.
Food Safety Reminders
Always verify that the internal temperature of the meat filling reaches 165°F (74°C) before serving. Use a meat thermometer inserted into the center of a shell to confirm doneness.
Frequently Asked Questions
Can I use cooked pasta shells instead?
While possible, uncooked shells produce superior results. Pre-cooked pasta tends to become mushy during the long smoking process, whereas raw shells achieve the perfect al dente texture.
What if I don’t have a smoker?
You can adapt this recipe for a regular oven by cooking at 175°C (350°F) for approximately 45-60 minutes. However, you’ll miss the distinctive smoky flavor that makes this dish special. Consider adding liquid smoke to the filling for a similar taste profile.
How do I prevent the bacon from burning?
Monitor the bacon closely during the final 30 minutes of cooking. If it’s browning too quickly, tent the shells with aluminum foil while allowing the internal temperature to continue rising.
Can I make smaller portions?
Absolutely! You can cut the manicotti shells in half before stuffing to create bite-sized appetizers. Reduce the cooking time to approximately 75-90 minutes total, checking frequently for doneness.
What’s the best wood for smoking?
Apple, cherry, or hickory wood work exceptionally well with this recipe. Hickory provides a stronger smoke flavor, while fruit woods offer a milder, slightly sweet taste that complements the bacon beautifully.
How do I store leftovers?
Store any leftover shotgun shells in the refrigerator for up to three days. Reheat in a 175°C (350°F) oven for 10-15 minutes to restore the bacon’s crispiness while warming the filling thoroughly.
Nutritional Information (Per Serving):
- Calories: 820
- Total Fat: 53g
- Total Carbohydrates: 29g
- Protein: 45g
Allergy Information: Contains dairy (cheese, cream cheese), gluten (pasta shells). Check barbecue sauce labels for additional allergens.
Essential Tools:
- Smoker or grill with smoking capability
- Large mixing bowl
- Pastry brush
- Baking sheet
- Meat thermometer