Ever wondered what happens when you stuff manicotti shells with seasoned beef, Italian sausage, and cheese, wrap them in bacon, and throw them on the smoker?
You get Smoked Shotgun Shells—one of the most ridiculous-looking and ridiculously good BBQ appetizers you can make.
We're loading these shells with ground beef, Italian sausage, cream cheese, sharp cheddar, and Barracks BBQ Rub & Tug. Then we're wrapping them in bacon, smoking them low and slow, and finishing them with a sticky Smokin' Soldier honey glaze.
The result? Smoky bacon on the outside, savory, cheesy meat on the inside, and a sweet BBQ finish.
BACON-WRAPPED. SMOKE-LOADED. BBQ-GLAZED.
What Are Smoked Shotgun Shells?
Smoked shotgun shells are a popular BBQ appetizer made by stuffing manicotti pasta shells with a seasoned meat-and-cheese mixture, wrapping them in bacon, and cooking them on a smoker.
The name comes from their resemblance to oversized shotgun shells.
Despite the pasta, this isn't your typical Italian dinner.
These things are essentially handheld BBQ bombs packed with meat, cheese, bacon, and smoke.
For our Barracks BBQ version, we're using a combination of ground beef and mild Italian sausage for a savory filling.
Rub & Tug seasons both the meat and the bacon, while Smokin' Soldier adds a smoky-sweet glaze at the finish.
Why You'll Love This Recipe
1. Loaded With Flavor
Ground beef, Italian sausage, cream cheese, and sharp cheddar create a rich, savory filling.
2. Everything Is Better Wrapped in Bacon
Thin-cut bacon surrounds the shells, helping protect the pasta while adding smoky, salty flavor.
3. The Perfect BBQ Glaze
Smokin' Soldier mixed with honey creates a sweet, sticky coating that complements the savory filling.
4. Great for Parties and Game Day
These are easy to serve as individual portions, making them a solid choice for cookouts, tailgates, and backyard gatherings.
5. You Can Prep Them Ahead
The shells need time in the refrigerator before smoking, so much of the preparation can be completed the night before.
The Secret to Smoked Shotgun Shells: Softening the Pasta
This is the part you absolutely cannot skip.
We're starting with uncooked manicotti shells, which means the pasta needs enough moisture to soften before and during cooking.
After stuffing the shells and wrapping them completely in bacon, refrigerate them covered for 8–12 hours.
This gives moisture from the filling and bacon time to begin softening the pasta.
However, refrigeration alone doesn't guarantee that every brand of dry manicotti will soften properly.
Check the shells before smoking.
If the pasta is still hard, don't assume another couple of hours on the smoker will magically fix it.
For a more reliable result, use manicotti shells that have been briefly pre-softened in hot water according to the package guidance before stuffing. You want them flexible enough to cook through without becoming so soft that they tear apart.
Nobody wants a mouthful of crunchy pasta wrapped in bacon.
Smoked Shotgun Shells | Bacon-Wrapped BBQ Recipe
Ingredients for Smoked Shotgun Shells
This recipe makes approximately 12 smoked shotgun shells.
Meat and Cheese Filling
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12 uncooked manicotti pasta shells
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½ lb ground beef (80/20)
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½ lb mild Italian sausage, casings removed
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4 oz cream cheese, softened
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1 cup shredded sharp cheddar cheese
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1 tbsp Barracks BBQ Rub & Tug
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1 finely diced jalapeño (optional)
Bacon Wrap
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12–24 slices thin-cut bacon, depending on length
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1 tbsp Barracks BBQ Rub & Tug
BBQ Glaze
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½ cup Barracks BBQ Smokin' Soldier BBQ Sauce
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2 tbsp honey
Why thin-cut bacon? It wraps more easily around the manicotti and generally renders more readily than thick-cut bacon during the smoking process.
What You'll Need
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Smoker or pellet grill
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Apple or cherry wood
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Wire cooking rack
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Large mixing bowl
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Piping bag or small spoon
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Meat thermometer
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Basting brush
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Heat-resistant gloves
Best Wood for Smoked Shotgun Shells
For this cook, we're using apple or cherry wood.
Both provide a relatively mild smoke profile that complements the bacon, beef, sausage, and sweet BBQ glaze.
Because these shells contain several bold ingredients, there's no need to overwhelm them with heavy smoke.
Let the meat, cheese, bacon, and seasoning do their jobs.
How to Make Smoked Shotgun Shells
Step 1: Prepare the Filling
In a large mixing bowl, combine:
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½ lb raw ground beef
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½ lb mild Italian sausage
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4 oz softened cream cheese
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1 cup shredded sharp cheddar
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1 tbsp Rub & Tug
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Optional finely diced jalapeño
Mix until the ingredients are evenly distributed.
Avoid overworking the meat mixture.
Keep the raw filling refrigerated whenever you're not actively working with it.
Step 2: Stuff the Manicotti Shells
Carefully fill each manicotti shell with the meat-and-cheese mixture.
Make sure the filling extends completely from end to end.
A piping bag can make this process easier, but a small spoon works too.
Take your time. Dry manicotti shells can crack if you apply too much pressure.
Step 3: Wrap Everything in Bacon
Wrap each stuffed manicotti shell completely in thin-cut bacon.
Overlap the bacon slightly as you wrap.
Depending on the length of your bacon slices, you may need two slices per shell.
Do not leave exposed pasta.
The bacon helps protect the pasta from drying out during smoking.
Step 4: Season the Bacon
Sprinkle the remaining tablespoon of Rub & Tug evenly over the bacon-wrapped shells.
This adds another layer of savory seasoning to the exterior.
Step 5: Refrigerate Overnight
Place the wrapped shells in a covered container and refrigerate for 8–12 hours.
This resting period helps moisture migrate into the pasta.
Before cooking, check whether the shells have softened.
If they're still hard, use a properly pre-softened batch of manicotti rather than risking undercooked pasta.
Step 6: Preheat the Smoker
Set your smoker to 250°F using apple or cherry wood.
Allow the smoker to reach a stable temperature.
Arrange the shotgun shells on a wire cooking rack, leaving space between them for airflow.
Step 7: Smoke the Shotgun Shells
Place the rack on the smoker.
Smoke for approximately 60–90 minutes, monitoring the internal temperature of the meat filling.
The bacon should begin rendering, and the exterior should develop color.
Use a meat thermometer to check the center of the filling.
Step 8: Prepare the Smokin' Soldier Honey Glaze
In a small bowl, combine:
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½ cup Smokin' Soldier BBQ Sauce
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2 tbsp honey
Mix until smooth.
When the filling approaches 160°F, brush the glaze generously over the shells.
Step 9: Increase the Heat
Increase the smoker temperature to 325–350°F.
Continue cooking to help render the bacon and set the glaze.
Watch closely during this stage because the honey adds sugar that can darken quickly.
Step 10: Cook to 165°F
Continue cooking until the center of each shell reaches 165°F and the bacon is rendered.
Because the filling combines raw ground beef and Italian sausage, checking the center temperature is essential.
Don't judge doneness by bacon color alone.
Step 11: Rest and Serve
Remove the shotgun shells from the smoker.
Allow them to rest for 5–10 minutes before slicing or serving.
The result should be tender pasta surrounding a fully cooked, cheesy meat filling, wrapped in smoky bacon with a sticky BBQ glaze.
Mission accomplished.
What Temperature Should You Smoke Shotgun Shells At?
Our recipe uses two cooking temperatures.
250°F — Initial Smoking Stage
This allows the shells to develop smoke flavor while the bacon begins rendering and the filling cooks.
325–350°F — Finishing Stage
The higher temperature helps finish the bacon and set the BBQ glaze.
The most important number is the internal temperature of the filling.
The center must reach 165°F.
How Long Do Smoked Shotgun Shells Take?
Plan for approximately 1½–2 hours of smoking, although actual cooking time can vary.
You'll also need approximately 30 minutes of hands-on preparation and an 8–12 hour refrigerated rest if using the overnight softening method.
For a Saturday afternoon cookout, preparing the shells Friday evening is a practical approach.
Common Mistakes When Making Smoked Shotgun Shells
1. Skipping the Refrigeration Period
Dry manicotti needs time and moisture to soften.
Skipping this step can leave you with crunchy pasta.
Even after refrigeration, check the shells before smoking.
2. Leaving Pasta Exposed
Exposed pasta can dry out and harden during smoking.
Make sure the bacon fully covers the shells.
3. Using Thick-Cut Bacon
Thick-cut bacon can take longer to render, potentially leaving the pasta and filling overcooked before the bacon reaches the desired texture.
Thin-cut bacon is the better choice for this recipe.
4. Overstuffing the Shells
Stuff the shells completely, but don't force so much filling inside that the pasta cracks.
5. Glazing Too Early
Applying a honey-based glaze too early can cause the sugars to darken excessively.
Wait until the filling approaches 160°F before brushing on the glaze.
6. Ignoring Internal Temperature
The bacon might look finished while the meat filling is still undercooked.
Always verify the center reaches 165°F.
Can You Make Smoked Shotgun Shells Ahead of Time?
Yes.
In fact, this recipe is designed for advance preparation.
You can stuff and wrap the shells the night before, then refrigerate them covered for 8–12 hours.
Keep the raw meat filling and assembled shells properly refrigerated.
When you're ready to cook, check the pasta texture, preheat the smoker, and follow the smoking instructions.
What to Serve With Smoked Shotgun Shells
These work as an appetizer or part of a larger BBQ spread.
Golden Ration | Smoked Cast Iron Cornbread
Buttery cornbread with crispy cast iron edges is an excellent side for the savory, bacon-wrapped shells.
Coleslaw
A crisp, tangy slaw helps balance the richness of the meat, cheese, and bacon.
Smoked Baked Beans
A classic backyard BBQ pairing.
Pickles and Pickled Jalapeños
Their acidity cuts through the richness and
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