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These smoked shotgun shells turned my regular barbecue game into something people actually talk about for weeks afterward. When you stuff manicotti shells with seasoned ground beef and sausage, wrap them in bacon, and smoke them low and slow, you get this incredible appetizer that looks impressive but is surprisingly manageable to make. I first saw these at my buddy's tailgate party and couldn't stop thinking about them until I figured out how to make my own version. Now they're my secret weapon whenever I want to blow people's minds at gatherings.
My neighbor came over last summer while I was making these for a block party. He watched me wrap bacon around pasta shells and thought I'd lost my mind, but after trying one he immediately asked for the recipe. Now he makes them for every family gathering and acts like he invented them himself.
What You'll Need
- Manicotti shells: The big tube pasta that's perfect for stuffing with all that good meat mixture
- Ground beef and hot Italian sausage: The combo gives you great flavor and texture when mixed together
- Sharp cheddar and cream cheese: Creates that creamy, melty center that oozes when you bite into them
- Diced onion and jalapeño: Adds crunch and heat that balances out all that rich meat and cheese
- Good barbecue sauce: You'll use it in the filling and for basting, so get something you actually like
- Quality bacon: This is what everyone sees first, so don't cheap out on thin, watery bacon
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Getting Them Ready
- Making the filling
- Mix your ground beef and Italian sausage together in a large bowl, don't cook them first, they'll cook perfectly in the smoker. Add the diced onion, both cheeses, minced jalapeño, and all your seasonings. Pour in about a third cup of barbecue sauce and mix everything together really well with your hands. It'll look like a lot of filling, but those shells hold more than you think.
- Stuffing the shells
- This is where it gets a little messy, but it's actually kind of fun. Take each uncooked manicotti shell and stuff it from both ends with that meat mixture, using your fingers or a small spoon to pack it in. Make sure you get rid of any air pockets because those can cause the shells to crack while smoking. Don't worry if some filling squeezes out, that's normal.
- The bacon wrap
- Wrap each stuffed shell with bacon, starting at one end and spiraling around to cover the whole thing. Some shells might need two pieces of bacon to cover completely, especially if you want to cover the ends. The bacon should be snug but not so tight that it squeezes the filling out of the shells.
- Sauce and smoke
- Brush barbecue sauce all over each bacon-wrapped shell and place them on your smoker at 250°F. After an hour, flip them over, add more barbecue sauce, and smoke for another hour or until the bacon is crispy and the internal temperature hits 160°F.
I learned the hard way that trying to rush these by cranking up the heat just burns the bacon before the pasta cooks through. Low and slow really is the way to go, even though it takes patience when they smell so amazing.
Perfect Serving Ideas
These are incredible right off the smoker when they're still hot and the cheese is melty. I usually put out some extra barbecue sauce for dipping, plus some ranch or blue cheese for people who want something cooling. They pair great with cold beer or sweet tea, and they're substantial enough that you don't need a ton of other appetizers.
Making Them Different
You can easily customize the filling based on what you like. Sometimes I add diced bell peppers or mushrooms to the meat mixture, or use different cheese combinations like pepper jack for more heat. Different barbecue sauce styles change the whole flavor profile - try a tangy vinegar-based sauce for Carolina flavor or a sweet molasses-based one for Kansas City style.
Planning and Prep
These are perfect for parties because you can stuff and wrap all the shells the night before, then just smoke them when guests arrive. Store the prepped shells covered in the refrigerator, and they'll actually be easier to handle when cold. Just add maybe 15 extra minutes to the cooking time if you're starting from cold.
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These smoked shotgun shells have become my signature party food because they never fail to impress people. There's something about the combination of smoky bacon, creamy cheese, seasoned meat, and tender pasta that just works perfectly together. They look way more complicated than they actually are to make, which makes you seem like some kind of barbecue genius when really you're just stuffing pasta shells and wrapping them in bacon.
Frequently Asked Questions
- → Do I need to cook the meat before stuffing?
- No! The meat mixture goes in completely raw. It will cook perfectly during the 2-hour smoking process.
- → Can I make these in the oven instead of a smoker?
- Yes, you can bake them at 350°F for about 45-60 minutes, but you'll miss out on that amazing smoky flavor.
- → How do I know when they're done?
- The bacon should be crispy and the internal temperature should reach 165°F. The shells will be tender and the filling fully cooked.
- → Can I prep these ahead of time?
- Absolutely! You can stuff and wrap them the day before, then smoke when ready to serve. Just keep them refrigerated.
- → What's the best way to serve these?
- Serve them whole as appetizers, or slice them into smaller rounds for bite-sized pieces. They're great with extra BBQ sauce for dipping.