Smoked Shotgun Shells (Bacon-Wrapped Stuffed Pasta Shells)

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Introduction:

Smoked Shotgun Shells are the ultimate BBQ appetizer or main dish that combines smoky flavor, crispy bacon, and cheesy, meaty goodness. Imagine jumbo pasta shells stuffed with a savory blend of seasoned ground meat and cheese, wrapped in bacon, and slow-smoked until the bacon is crisp and the filling is juicy. These eye-catching “shells” are packed with flavor and deliver the kind of mouthwatering bite that’s perfect for BBQs, game days, or weekend smoking sessions.

Origin:

Shotgun Shells originated as a creative twist in the BBQ community, primarily gaining traction in the Southern U.S., where pitmasters love experimenting with smoked meat and unexpected ingredients. The name comes from the resemblance of the bacon-wrapped tubular shells to shotgun shells, and the flavor truly delivers a bang!

Ingredients (Makes 12 shells):

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For the Filling:

  • 1 lb (450g) ground beef or ground sausage (or a mix)
  • ½ cup shredded cheddar or mozzarella cheese
  • 2 tbsp barbecue sauce or ketchup
  • 1 tsp garlic powder
  • 1 tsp onion powder
  • ½ tsp smoked paprika
  • Salt and pepper to taste

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Additional:

  • 12 uncooked manicotti shells or cannelloni tubes
  • 12 slices of thin-cut bacon (1 per shell)
  • ½ cup BBQ sauce (for glazing)

Optional Add-Ins:

  • Jalapeños or diced green chilies for spice
  • Cream cheese or ricotta in the filling for creaminess
  • Fresh parsley or chives for garnish
  • Add chopped cooked mushrooms or caramelized onions for depth

Instructions:

Step 1 – Make the Filling:

  1. In a large bowl, mix ground meat, shredded cheese, BBQ sauce, and seasonings until well combined.
  2. Spoon the mixture into a piping bag or use a small spoon to stuff the uncooked pasta shells. Pack tightly.

Step 2 – Wrap the Shells:

  1. Wrap each stuffed shell in a slice of bacon, overlapping slightly and tucking the ends if needed.
  2. Place on a baking rack or tray and refrigerate for at least 4 hours or overnight to allow the pasta to soften slightly before smoking.

Step 3 – Smoke the Shells:

  1. Preheat smoker to 250°F (120°C).
  2. Place the shells directly on the smoker grate or on a wire rack.
  3. Smoke for about 2 to 2.5 hours, or until internal temp of filling reaches 165°F (74°C) and bacon is cooked.

Step 4 – Glaze and Finish:

  1. In the last 15 minutes of smoking, brush the shells with BBQ sauce.
  2. Let glaze set and caramelize slightly before removing from smoker.

Step 5 – Rest and Serve:

  • Let rest for 5–10 minutes. Slice in halves or serve whole.

Tips for Success:

  • Do not pre-boil the shells. Letting them rest filled overnight allows the moisture from the filling to soften them.
  • Use thin-cut bacon to ensure it crisps up; thick bacon may stay rubbery.
  • Chill before smoking — this helps shells hold their shape and improves texture.
  • For crispier bacon, increase temp to 300°F for the last 15 minutes or finish under the broiler.

Serving Recommendations:

  • Serve with:
    • Extra BBQ sauce or ranch for dipping
    • A side of coleslaw, baked beans, or grilled corn
    • Cold beers or iced tea
  • Great for:
    • Game day spreads
    • Summer cookouts
    • Meat lover’s brunch
    • Tailgating parties

Nutrition (Per Shotgun Shell – Approximate):

  • Calories: 290
  • Protein: 16g
  • Fat: 19g
  • Carbohydrates: 9g
  • Sugar: 4g
  • Sodium: 470mg

Nutritional content will vary based on filling choices and bacon thickness.

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