Smoked Shotgun Shells are an irresistible BBQ treat that has quickly become a backyard staple for those who love delicious, smoky flavors and crave that wow-factor at every gathering. Imagine perfectly seasoned Italian sausage, creamy melty cheese, and tangy barbecue sauce all wrapped up inside a tender manicotti shell, then enveloped in crispy bacon and slow-smoked until everything melds together in the most mouthwatering bite possible. This dish is a surefire crowd-pleaser, and it’s surprisingly simple to prepare—even for beginner smokers!

Smoked Shotgun Shells Recipe - Recipe Image

Ingredients You’ll Need

It only takes a handful of ingredients to create the magic that is Smoked Shotgun Shells, but each one brings something unique to the table. From gooey cheese to flavorful sausage, these components work together to pack every bite with taste, texture, and eye-catching color.

Italian sausage: Use mild or spicy, depending on your preference; it forms the flavorful, meaty base of the filling.
Mozzarella cheese: Shreds easily and brings that classic, gooey cheese pull everyone loves.
Cream cheese: Softened cream cheese adds a creamy texture and helps bind the filling together.
Manicotti shells: The surprise “shells” of these shotgun shells, they hold everything together and become perfectly tender as they smoke.
Bacon: Wraps each shell, infusing smoky flavor and providing a crisp, savory exterior.
Barbecue sauce: Gives that sticky-sweet, glossy finish and helps to balance the richness of the cheese and sausage.
Barbecue rub: Adds bold flavor to both the filling and the bacon-wrapped shells; use your favorite blend or homemade mix.

How to Make Smoked Shotgun Shells

Step 1: Prep Your Filling

Start by softening your cream cheese so it combines smoothly. Shred the mozzarella cheese and toss it into a bowl with the Italian sausage, softened cream cheese, and a spoonful of barbecue rub. Mix everything together thoroughly—using your hands is easiest—until you have a creamy, sausage-packed filling. The aroma at this stage already hints at what’s coming!

Step 2: Fill the Manicotti Shells

Now for the fun part: stuffing the manicotti shells. You can use a piping bag with a wide tip, or gently work the filling in with a small spoon and your fingers. Take your time; you want each shell packed full so there are no empty bites. The combination of meats and melting cheeses inside will be well worth the extra effort.

Step 3: Encase in Bacon

Wrap each stuffed manicotti shell completely with strips of bacon, overlapping the ends to secure them. This not only locks in the flavor but ensures the shells stay sealed as they smoke. It’s amazing to watch how the bacon crisps up and brings everything together in one neat, savory package.

Step 4: Season and Refrigerate

Sprinkle another layer of barbecue rub over the bacon-wrapped shells for extra depth of flavor. Pop them in the refrigerator for at least four hours (or even overnight if you plan ahead). This chilling step hydrates the pasta just enough, so it softens perfectly on the smoker.

Step 5: Smoke to Perfection

Fire up your smoker to 250°F, arrange the shells on the grate, and let them smoke for an hour. Turn them halfway through for even cooking. This slow-smoking process infuses all those layers—meat, cheese, pasta, and bacon—with irresistible wood-fired flavor.

Step 6: Crisp and Glaze

Turn the heat up to 350°F for about fifteen minutes to finish crisping up the bacon. Then, brush each shell generously with barbecue sauce. A quick final blast infuses them with a sweet, shiny glaze that ties together every flavorful element of these Smoked Shotgun Shells.

How to Serve Smoked Shotgun Shells

Garnishes

To add a fresh pop and a gorgeous finish, sprinkle your Smoked Shotgun Shells with sliced green onions or fresh parsley. You could also go bold with a drizzle of extra barbecue sauce or a scattering of diced pickles or jalapeños for a little heat and tang. They’ll look as delicious as they taste!

Side Dishes

These savory shells pair perfectly with plenty of classic barbecue sides—think crisp coleslaw, smoked baked beans, or a light green salad to cut through the richness. Cornbread or potato wedges are also great choices if you want something extra hearty to round out the meal.

Creative Ways to Present

For a party, slice each Smoked Shotgun Shell in half so guests can nibble and sample other dishes too. Pile them onto a wooden platter, garnish with fresh herbs, and set out toothpicks for easy grabbing. You can even serve them with a trio of dipping sauces for a fun, interactive spread.

Make Ahead and Storage

Storing Leftovers

If you have leftovers (which is rare!), let your Smoked Shotgun Shells cool completely, then transfer them to an airtight container. They’ll keep in the fridge for up to three days, making them perfect for next-day lunches or midnight cravings.

Freezing

To freeze, wrap each fully cooled shell tightly in plastic wrap, then place them in a freezer bag or airtight container. They’ll last up to two months—just remember to label them with the date. Thaw overnight in the refrigerator before reheating for best results.

Reheating

Warm your Smoked Shotgun Shells gently in the oven at 325°F until hot throughout, about 15–20 minutes. You can brush them with a little extra barbecue sauce before reheating to revive that sticky, glossy finish. Avoid microwaving if possible to keep the bacon crisp and irresistible.

FAQs

Can I use a different type of sausage for Smoked Shotgun Shells?

Absolutely! Spicy chorizo or breakfast sausage work beautifully. Mixing up the type of sausage lets you tailor the flavor profile exactly to your crowd’s taste.

Do the manicotti shells need to be precooked?

Nope, that’s the beauty of this recipe. The uncooked shells soften and cook through perfectly as they smoke, soaking up all the juicy goodness of the filling and bacon.

Can I make Smoked Shotgun Shells in the oven?

Yes, you can bake them if you don’t have a smoker. Use a rack over a baking sheet at 350°F, and add a touch of liquid smoke to the filling for extra BBQ flavor. They won’t be quite as smoky but will still be delicious!

What types of wood chips are best for smoking?

Hickory and applewood are classic choices that pair wonderfully with pork and cheese. Cherry wood also lends a subtle sweetness. Choose your favorite for even more flavor adventure.

How do I keep the bacon from unraveling while smoking?

Wrapping the bacon strips snugly and slightly overlapping them usually does the trick. If you’re worried, use toothpicks to secure them during smoking—just remember to remove them before serving!

Final Thoughts

If you’re looking for something fun and unforgettable to serve at your next cookout, give these Smoked Shotgun Shells a try. They’re equal parts showstopper and comfort food, and there’s no better feeling than watching everyone reach for seconds. Grab your smoker, gather your friends, and enjoy the smoky, cheesy goodness!

Smoked Shotgun Shells Recipe

★★★★★

5.1 from 21 reviews

Author: Noah
Total Time: 1 hour 45 minutes
Yield: 6 servings
Diet: Gluten Free

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Description

These Smoked Shotgun Shells are a delicious and unique twist on classic stuffed pasta dishes. The combination of Italian sausage, cheeses, and bacon, all smoked to perfection, creates a flavor explosion that will impress your guests.

Ingredients

Italian Sausage:

1 lb

Mozzarella Cheese:

4 oz

Cream Cheese: