Smoked Shotgun Shells: The Ultimate Bacon-Wrapped, Sausage and Cheese Stuffed Appetizer
Prepare to amaze your guests with these incredible Smoked Shotgun Shells – an appetizer that’s guaranteed to be the star of any party or holiday celebration! Imagine tender pasta shells, generously stuffed with a savory, spicy blend of sausage, cheese, and hot peppers, all wrapped in crispy bacon, slow-smoked to perfection, and finally smothered in a sweet, tangy BBQ sauce. This isn’t just another appetizer; it’s a culinary experience that combines the irresistible flavors of smoked meats with the comforting satisfaction of pasta, creating a truly unforgettable bite.
What Exactly Are Smoked Shotgun Shells?
Smoked Shotgun Shells are a creative and incredibly popular appetizer, aptly named for their cylindrical shape, which resembles a shotgun shell. At their core, these delectable bites feature manicotti pasta shells, which serve as the perfect vessel for a hearty filling. Typically, the shells are packed with a rich mixture of ground meat, often sausage, combined with melted cheese and various seasonings. What elevates them to another level is the addition of bacon, meticulously wrapped around each stuffed shell, and then the magic of low-and-slow smoking. This cooking method infuses every component with a deep, smoky flavor that’s simply irresistible. Our recipe takes it up a notch with a delightful kick from hot peppers and a finishing glaze of luscious BBQ sauce, creating a complex flavor profile that will have everyone reaching for more.
While the name might sound intense, these “shotgun shells” are nothing but pure comfort food with a gourmet twist. They offer a fantastic textural contrast: the slightly firm yet tender pasta, the savory and cheesy filling, the crispiness of the bacon, and the sticky, sweet coating of BBQ sauce. They’re relatively easy to prepare, making them a fantastic choice for both seasoned pitmasters and home cooks looking to try something new and impressive on their smoker.
Why Smoke Your Shotgun Shells? The Flavor Advantage
While some recipes might call for baking these stuffed pasta shells, smoking them offers a distinct and unparalleled flavor advantage that truly sets this appetizer apart. The smoker imparts a rich, nuanced depth that you simply can’t achieve in a conventional oven. As the shells slowly cook, the wood smoke penetrates the bacon, sausage, and even the pasta itself, creating layers of savory goodness. The bacon renders beautifully, becoming incredibly crisp and flavorful, while the sausage and cheese filling absorbs that signature smoky essence. Furthermore, the low and consistent temperature of a smoker allows the ingredients to meld together seamlessly, resulting in a more tender pasta and a perfectly cooked filling without drying it out. This method ensures every bite is packed with complex, mouth-watering flavor that will have your guests asking for the recipe.
Gather Your Ingredients: What You’ll Need
One of the best parts about making Smoked Shotgun Shells is that all the ingredients are readily available at most local grocery stores. However, be prepared for a potential scavenger hunt for the manicotti shells themselves, as they can sometimes be out of stock depending on your location and store. Don’t be discouraged if you have to check a couple of places!
- Manicotti Shells (pasta): These large, hollow pasta tubes are essential for holding the delicious filling. Look for the dry, uncooked variety.
- Jimmy Dean Breakfast Sausage (regular or hot): We recommend the “hot” variety for an extra kick, but regular works perfectly if you prefer a milder flavor. You can also experiment with other ground sausages like Italian sausage for a different profile.
- Bacon: Thin-cut bacon is crucial for achieving that desirable crispy texture during smoking. Thick-cut bacon tends to stay chewy.
- Cheddar Cheese: Shredded cheddar melts beautifully and adds a sharp, savory note to the filling. Feel free to explore other good melting cheeses like Monterey Jack or a Colby-Jack blend.
- Red Bell Pepper: Adds a touch of sweetness and vibrant color, balancing the richness of the meat and cheese.
- Jalapeño: Provides a moderate level of heat and a fresh, bright flavor. If you want more heat, leave some of the seeds and membranes in; for less, remove them entirely.
- Serrano Pepper: For those who love serious spice, the serrano pepper delivers a more intense heat than the jalapeño, taking these shotgun shells to the next level. Adjust the quantity to your preference.
- BBQ Sauce: A sweet barbecue sauce is highly recommended as it perfectly complements the smoky flavors and the heat from the peppers. Use your favorite brand!
Video – How to make shotgun shells (step-by-step)
Mastering the Art of Smoked Shotgun Shells: A Step-by-Step Guide
Crafting the perfect Smoked Shotgun Shells is a rewarding process that results in a truly unforgettable appetizer. Follow these detailed steps to ensure your pasta is perfectly cooked, your filling is cheesy and delicious, and your bacon is wonderfully crispy. We’ll guide you through every critical stage, from preparing the pasta to the final smoky glaze, making sure you achieve absolute perfection.
The Crucial Step: Par-Boiling the Manicotti Shells
This initial step is absolutely non-negotiable for achieving perfectly cooked pasta in your smoked shotgun shells. Skipping the par-boiling will almost certainly result in undercooked, tough pasta, which can ruin the entire dish. The goal here is not to fully cook the manicotti but to soften it enough so that it can be easily stuffed and will finish cooking to a tender, edible consistency during the smoking process.
Start by bringing a large pot of water to a rolling boil. While the water heats up, prepare a separate, generously sized bowl of ice water. This ice bath is essential for stopping the cooking process immediately after par-boiling. Once the water is boiling, carefully add your uncooked manicotti shells. Boil them for precisely 4 minutes. This short cooking time is just enough to soften the pasta without making it too pliable or prone to breaking. As soon as the 4 minutes are up, use tongs or a slotted spoon to swiftly remove the shells from the boiling water and immerse them directly into the ice water. Let them sit in the ice bath for a few minutes until completely cooled. This quick chill prevents the pasta from cooking any further, ensuring it retains a slight firmness that will allow it to hold up beautifully on the smoker. Remember, the pasta will continue to cook on the smoker, so resist the urge to boil them longer than recommended.
Once cooled, gently remove the shells from the ice water and pat them dry with paper towels. This drying step is important to prevent excess moisture from interfering with the stuffing process and to help the bacon adhere better later on.
Crafting the Irresistible Stuffing Mixture
The heart of your Smoked Shotgun Shells lies in this flavorful, savory stuffing. In a large mixing bowl, combine the ground sausage, shredded cheddar cheese, and your finely chopped red bell pepper, jalapeño, and serrano pepper. For the best results, get your hands in there and mix everything together thoroughly. Wearing food-safe gloves can make this process more comfortable and hygienic, ensuring all ingredients are evenly distributed throughout the sausage mixture.
Customization Tip: If you’re not a fan of spicy food, or if you’re serving a crowd with varying heat tolerances, it’s easy to adjust the spice level. Simply opt for regular pork breakfast sausage instead of the hot variety, and feel free to omit the jalapeño and serrano peppers entirely. You can replace them with more red bell pepper or even finely diced onion for added flavor without the heat. Conversely, for an extra fiery kick, consider adding a pinch of cayenne pepper or a dash of your favorite hot sauce to the mixture. Don’t limit yourself to breakfast sausage; Italian sausage (sweet or hot) can also be an excellent substitute, offering a different but equally delicious flavor profile.
Expertly Stuffing the Manicotti Shells
This step requires a gentle touch and a bit of patience, but it’s far from rocket science. The goal is to fill each par-boiled manicotti shell completely and evenly without causing it to split. Again, wearing food-safe gloves is highly recommended for this task, as it keeps your hands clean and makes handling the meat mixture easier.
Begin by taking one end of a manicotti shell and gently pushing about half of the sausage mixture into it using your finger or a small spoon. Once that side is half-filled, flip the shell over and repeat the process from the opposite end, filling the remaining half. This dual-sided approach helps distribute the filling more evenly and reduces the risk of the shell breaking under pressure. Be careful not to overstuff, as this can also lead to splits. Once all your manicotti shells are plump and full, they’re ready for their bacon embrace!
The Bacon Wrap: Adding Flavor and Crispiness
Just like with smoked jalapeño poppers, wrapping your stuffed shells in bacon adds an incredible layer of flavor and texture. The choice of bacon thickness here is crucial: always opt for thin-cut bacon over thick-cut. Thin bacon will cook through more efficiently on the smoker, rendering its fat and becoming beautifully crispy, whereas thick bacon tends to remain chewy and soft.
To wrap each shell, take a strip of bacon and start at one end of the stuffed manicotti. Begin wrapping the bacon in a spiral fashion around the shell, ensuring there are no large gaps. Depending on the length of your bacon strips and the size of your shells, you’ll likely need 1-2 pieces of bacon per shell. We highly recommend using two pieces per shell for maximum bacon coverage and flavor. Don’t worry if it looks like a lot of bacon; it will shrink considerably during the cooking process, resulting in a perfect, crispy coating.
To secure the bacon in place and prevent it from unraveling during smoking, use one or two toothpicks per shell. Simply push the toothpicks through the bacon and partially into the pasta, making sure they hold the ends of the bacon strips firmly. These toothpicks will be removed before serving. If you’ve never experimented with smoking bacon before, prepare to be amazed. Smoked bacon delivers a flavor profile that is truly next-level, adding an extraordinary depth to these shotgun shells.
Smoking Your Masterpiece: Cooking the Bacon-Wrapped Shotgun Shells
Now that your Smoked Shotgun Shells are assembled, it’s time for the exciting part: getting them onto the smoker to transform into crispy, smoky, and utterly delicious appetizers. This process is where all the flavors meld together and the bacon crisps up beautifully.
Prepping Your Smoker: Fire It Up!
Begin by firing up your smoker and preheating it to a consistent temperature of 270°F (approximately 132°C). The type of smoker isn’t critical; whether you’re using a pellet grill, an offset smoker, or an electric smoker, the key is maintaining a stable temperature. For this recipe, we highly recommend using mild wood pellets or wood chips to impart a balanced smoky flavor that won’t overpower the other ingredients. Applewood pellets or hickory wood are excellent choices, offering a sweet and robust smoke that complements the sausage, cheese, and BBQ sauce wonderfully. Cherry wood can also provide a beautiful color and fruity smoke note.
I personally find my Recteq smoker delivers fantastic results for this recipe, but I’ve also had great success with my Traeger 780 wood pellet grill (affiliate Link). Consistency in temperature is more important than the brand of smoker you use.
Once your smoker reaches the target temperature and is producing clean smoke, carefully place the bacon-wrapped shotgun shells directly onto the grill grates. Arrange them with a little space in between to allow for even smoke circulation and cooking. You don’t need to flip the shells during the smoking process; the consistent heat from the smoker will cook them evenly from all sides. Smoke the shells until the internal temperature of the sausage filling reaches 155°F (approximately 68°C). This usually takes about 1.5 hours, but always rely on your meat thermometer for accuracy. At this point, the pasta will be tender, and the bacon will be mostly rendered and starting to crisp.
The Finishing Touch: Baste with BBQ Sauce
Once your smoked shotgun shells have reached an internal temperature of 155°F, it’s time for the final flavor boost. Using a basting brush, generously “paint” your favorite sweet barbecue sauce over both sides of each shotgun shell. The sweetness of the BBQ sauce provides a perfect counterpoint to the spiciness of the peppers in the filling and the richness of the bacon and sausage. It also helps to create a beautiful, glossy glaze.
After coating all the shells, return them to the smoker for another 5-10 minutes. This short period allows the BBQ sauce to set and caramelize slightly, adhering to the shells and creating a delicious sticky coating. More importantly, it brings the internal temperature of the sausage filling up to a safe 160°F (71°C), ensuring it’s fully cooked and ready to enjoy. Once they reach the desired temperature and the sauce is set, carefully remove the smoked shotgun shells from the smoker using tongs and transfer them to a serving platter.
Serving Suggestions & Unforgettable Flavor
Before presenting these incredible appetizers to your eager guests or family, a little bit of prep goes a long way. This is the perfect time to carefully remove all the toothpicks from the bacon-wrapped shells. By now, the bacon will have rendered and crisped, holding its shape around the pasta without the need for the toothpicks.
For an optimal party finger food experience, especially when serving alongside other appetizers, we recommend cutting each smoked shotgun shell in half. A sharp knife (affiliate link) will make clean cuts, showcasing the vibrant filling inside. Cutting them in half makes them easier to handle and ensures each guest can enjoy a perfect, bite-sized portion without feeling overwhelmed.
The flavor profile of this smoked shotgun shell recipe is truly unparalleled. The smoky notes from the wood, combined with the savory richness of the sausage, the creamy melted cheddar, and the subtle kick from the peppers, all harmoniously blend together. The sweet BBQ glaze provides that final touch of sticky, tangy goodness. Every bite is an explosion of texture and flavor – from the tender pasta and hearty filling to the crispy bacon and sticky sauce. This appetizer is an absolute showstopper, and everyone will undoubtedly fall in love with its unique and delicious appeal!
Storing Leftovers & Reheating Tips
It’s rare to have leftovers of these delicious Smoked Shotgun Shells, but if you do, they store exceptionally well. To keep them fresh and flavorful, place any remaining shells in an airtight container and refrigerate them promptly. They will stay good for 3-4 days in the fridge, making them perfect for a quick snack or meal later in the week.
When you’re ready to enjoy your leftovers, reheating them in the oven is the best method to maintain their texture and crispiness. Preheat your oven to 375°F (190°C). Arrange the shotgun shells on a baking sheet, ensuring they are not overcrowded. Heat for about 10-15 minutes, or until they are heated through and the bacon starts to crisp up again. Avoid reheating in the microwave, as it can make the bacon soggy and the pasta chewy. A toaster oven can also work well for smaller batches, providing similar crisping results.
Pro Tips for Perfect Smoked Shotgun Shells
Achieving perfection with your Smoked Shotgun Shells is all about mastering a few key techniques and understanding the nuances of the smoking process. These pro tips will guide you to consistently turn out amazing results, ensuring your appetizer is always a hit:
- Always Cook to Internal Temperature, Not a Specific Time: While our recipe provides estimated cooking times, these are merely guidelines. The most accurate way to ensure your sausage filling is cooked through and safe to eat (160°F / 71°C) without overcooking the pasta is to use a reliable meat thermometer. This practice prevents dry, overcooked sausage and ‘burnt’ or tough pasta ends, guaranteeing a juicy, tender result every time.
- Pair with a Sweet BBQ Sauce for Optimal Flavor Balance: The heat from the jalapeño and serrano peppers, combined with the savory richness of the sausage and bacon, is beautifully balanced by a sweet barbecue sauce. The sugars in the sauce caramelize on the smoker, creating a delightful sticky glaze that adds another layer of complexity to the flavor profile.
- Thin-Cut Bacon is Superior to Thick-Cut: For crispy bacon that fully renders its fat during the smoking process, thin-cut bacon is the only way to go. Thick-cut bacon tends to remain chewy and doesn’t achieve the desired texture, which can detract from the overall experience of the dish.
- Par-Boil the Pasta for Precisely 4 Minutes: This step is critical and cannot be skipped or altered significantly. Boiling the manicotti shells for exactly 4 minutes softens them just enough for stuffing while ensuring they won’t be undercooked and hard after their time on the smoker. Remember to transfer them immediately to an ice bath to stop the cooking process and maintain their structural integrity.
Complementary Appetizer Pairings
Smoked Shotgun Shells are undeniably a show-stopping appetizer, but they truly shine when presented alongside a diverse selection of other crowd-pleasing bites. Pairing them with other delicious starters can create a memorable spread for any occasion. Here are some fantastic appetizer ideas that complement the rich, smoky, and spicy flavors of your shotgun shells:
- Smoked Jalapeño Poppers – Jerkyholic: If your guests love a bit of heat and smoky flavor, these are a natural fit. Cream cheese-filled jalapeños wrapped in bacon and smoked are always a hit.
- Pigs in a Blanket – Amanda’s Cooking: A classic for a reason! These savory mini sausages wrapped in flaky pastry offer a comforting contrast to the bolder flavors of the shotgun shells.
- Caprese Skewers – Cooking For My Soul: For a lighter, fresher option, Caprese skewers (cherry tomatoes, mozzarella balls, and basil leaves drizzled with balsamic glaze) provide a refreshing palate cleanser.
- Smoked Deviled Eggs – Jerkyholic: Adding a smoky twist to deviled eggs introduces a familiar favorite with an unexpected depth of flavor that aligns perfectly with the smoked theme.
- Shrimp Cocktail – Bacon Fatte: The elegance and cool, briny taste of shrimp cocktail offer a sophisticated counterpoint, providing a contrasting texture and temperature.
By offering a variety of appetizers, you ensure there’s something for every palate, making your gathering a culinary success.
Smoked Shotgun Shells
Ingredients
- 12-16 each manicotti shells
- 2 lbs jimmy dean sausage (Hot)
- 8 oz cheddar cheese (Shredded)
- 2 lbs bacon (Thin cut)
- 1 each red bell pepper (Chopped)
- 1 each jalapeno (Chopped)
- 1 each serrano pepper (Chopped)
- ½ cup barbecue sauce (Sweet)
Equipment
Instructions
- Bring a large pot of water to boiling and add manicotti shells. Boil for 4 minutes then remove and place shells directly into a bowl of ice water to stop the pasta from cooking further.
- While pasta is in water bath, mix the sausage, cheese, bell pepper, jalapeño, & Serrano pepper together in a separate bowl.
- Remove pasta from water and pat dry with paper towels. Stuff the shells with the sausage mixture by hand. Using your fingers and starting at one side of the pasta shell, stuff it ½ full with sausage filling. Now starting from the other end, fill the remaining half of the shell with more stuffing being careful to not break the pasta shell.
- Once stuffed, wrap 2 pieces of bacon around each manicotti shell using toothpicks to keep bacon in place.
- Place stuffed shells directly on grill rack of a smoker that has been pre-heated to 270°F. Smoke until an internal temperature of 155°F, about 1.5 hours. No need to rotate shells on grill when smoking.
- Once 155°F IT is reached, baste a sweet BBQ sauce on both sides of the stuffed shotgun shells and continue to smoke 10 minutes longer until an IT of 160°F is reached and barbecue sauce is adhered to shells.
- Remove from smoker and place on serving platter. Remove toothpicks and cut shells in ½ for a perfect party finger food sized appetizer. Enjoy!
- Please rate and leave a comment if you made these. Thanks!
Pro Tips
- Cook to internal temperature, not a specific time. This will prevent overcooking and having ‘burnt’ ends of the pasta.
- Use a sweet BBQ sauce to compliment the spicy peppers in the pasta filling.
- Thin cut bacon will cook better and is better to use over thick cut bacon.
- Par boil the pasta for 4 minutes before stuffing, otherwise the pasta will be undercooked.