Masters of kitchen
Smoked Shotgun Shells are everything you didn’t know you needed at your next BBQ. This over-the-top appetizer has exploded on social media—and for good reason. Imagine crispy, smoky bacon wrapped around tender pasta tubes stuffed with a juicy meat and cheese filling. Now imagine that whole thing slow-smoked to savory perfection. Sounds like a flavor bomb, right? That’s exactly what it is.
In simple terms, Smoked Shotgun Shells are uncooked manicotti shells that get stuffed with seasoned ground meat and cheese, tightly wrapped in bacon, and then smoked until the bacon is perfectly crisp and the filling is juicy and hot. The pasta softens during the smoking process, soaking up all that smoky BBQ flavor.
Why do people love them? Because they’re fun to make, even more fun to eat, and the flavor is next-level. They’re also great for impressing guests at backyard cookouts or game-day gatherings.
Bold Tip: These make perfect party food—serve them sliced up as appetizers or whole as a main course with a side of slaw or beans!
Origins & The Viral BBQ Craze
Like many modern BBQ creations, Smoked Shotgun Shells gained traction thanks to TikTok, Instagram, and YouTube, where pitmasters and home cooks began sharing their unbelievably delicious results. Once folks saw bacon-wrapped pasta oozing with cheese, it was game over—this dish went viral.
Though it may seem like a wild invention, it’s got roots in the bold, meat-loving world of Texas-style BBQ. Backyard grillers have long been experimenting with nontraditional ingredients on the smoker, and this one stuck hard.
Is it traditional? Not even close. But it is fun, approachable, and packed with smoky satisfaction—perfect for anyone who loves putting a creative twist on their cookout.
Key Ingredients You’ll Need (Without Overwhelming You)
You don’t need a long shopping list to make these happen. Here are the essentials:
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Uncooked manicotti shells (yes, keep them dry!)
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Ground beef, pork, sausage, or a combo
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Shredded cheese (cheddar, mozzarella, pepper jack—your call)
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Bacon, preferably thick-cut
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BBQ rub or your favorite seasoning blend
Want to take it up a notch? Add diced jalapeños, a BBQ sauce glaze, or mix in a little cream cheese for added richness in the filling.
Tip: Thick-cut bacon wraps better and gives you that crisp, smoky bite without burning before the filling is cooked.
The Right Equipment for BBQ Success
Don’t worry—you don’t need a professional setup to make these shells a hit. Here’s what you will want on hand:
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Smoker or pellet grill (like Traeger, Pit Boss, or Z Grills)
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A reliable meat thermometer
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A wire cooling rack or disposable aluminum tray
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Toothpicks (optional, but useful for securing bacon edges)
Pro Tip: Place your shells on a wire rack inside your smoker for better air circulation. This helps your bacon crisp up evenly without flipping mid-smoke.
Prepping Shotgun Shells Like a Pitmaster
This is where the magic starts—and it’s easier than it looks. Let’s walk through the process step by step:
Step 1: Mix the Filling
In a large bowl, combine your ground meat with shredded cheese and seasonings. This mixture should be slightly sticky so it holds together well inside the shell. Optional: mix in chopped jalapeños or a dollop of cream cheese for extra flavor.
Step 2: Stuff the Manicotti
Carefully fill each uncooked manicotti shell with the meat mixture. A piping bag or your fingers work best. Be sure to fill completely without over-packing—the meat will expand slightly as it cooks.
Step 3: Wrap in Bacon
Take 2 slices of bacon per shell and wrap around the pasta, overlapping slightly so it fully covers the surface. Try to cover the shell from end to end.
Step 4: Optional Chill Time
Place the wrapped shells on a tray and refrigerate for at least 4 hours, or overnight if possible. This gives the pasta time to start softening and helps the shells hold their shape.
Step 5: Prep for Smoking
Before placing them on the smoker, you can sprinkle a little more BBQ rub over the top. Set them on a wire rack for better airflow and smoke circulation.
Tips for Success
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Don’t overstuff the manicotti. The filling can expand slightly during cooking and cause the bacon to split.
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Avoid boiling the pasta first—it will soften naturally in the smoker.
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Chilling is key: It prevents blowouts and helps the bacon set better on the shell before cooking.
Up next: we’ll dive into the smoking process, flavor variations, serving ideas, and how to store these addictive shells for later!
Smoking Your Shotgun Shells to Perfection
Getting that perfectly smoky, juicy, and crispy result comes down to time, temp, and a little patience. Here’s how to do it right:
Temperature: Preheat your smoker to 250°F to 275°F. This low and slow method ensures the pasta softens fully while allowing the bacon to crisp without burning.
Time: Smoke the shells for 90 to 120 minutes, depending on size and how well your smoker retains heat.
Wood Chips: For the best flavor, stick with hickory (bold and smoky), mesquite (intense and earthy), or applewood (milder, sweet smoke).
Add BBQ glaze during the last 15 minutes of smoking if you like a sticky, glossy finish. Brush it on gently and let it caramelize right on the bacon.
Internal Temp Check: Always make sure the internal temperature of the filling reaches at least 160°F. This ensures the ground meat is fully cooked.
Want extra crispy bacon? Pop the finished shells under your broiler for 1–2 minutes or sear them quickly on a hot grill. Just watch closely so nothing burns.
Creative Variations to Try
Once you master the basics, try these flavor twists:
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Spicy Kick: Mix in diced jalapeños, crushed red pepper, or a few dashes of your favorite hot sauce into the filling.
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Extra Cheesy: Blend cheeses like cheddar, pepper jack, and cream cheese for a gooey, decadent bite.
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Sweet & Savory: Rub brown sugar onto the bacon before smoking for a candied outer crust.
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Tex-Mex Style: Add taco seasoning to the meat and stuff with a queso cheese blend.
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Vegetarian Version: Use plant-based sausage and vegan cheese for a meatless version that still delivers.
Bold Tip: Create a sampler platter with different flavors so guests can pick their favorites!
What to Serve with Smoked Shotgun Shells
These rich, smoky shells pair beautifully with BBQ sides or finger foods:
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Classic BBQ Sides: Serve alongside creamy coleslaw, baked beans, or mac and cheese.
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Party Style: Add them to a finger food board with smoked wings, sliders, or ribs.
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Dips & Sauces: These shells love a good dip—try ranch, chipotle mayo, or BBQ sauce for dunking.
They’re hearty enough to be a main dish, but versatile enough for party platters!
Storage, Freezing & Reheating Tips
If you’re lucky enough to have leftovers (good luck!), here’s how to keep them tasting great:
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Refrigerate: Store in an airtight container in the fridge for up to 4 days.
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Freeze Uncooked: Freeze assembled, uncooked shells on a tray first. Once solid, transfer to a freezer bag. Smoke from frozen—just add extra time.
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Reheat Properly: Use an oven or air fryer at 350°F until heated through. This helps preserve texture.
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Avoid the Microwave: It tends to make pasta chewy and bacon rubbery—no thanks!
Troubleshooting & Expert Tips
Even BBQ pros hit a few snags. Here’s how to fix common issues:
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Crunchy Pasta? Chill longer before smoking—this allows moisture to soften the shells.
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Bacon Not Crisp? Hit it with the broiler or sear briefly after smoking.
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Shells Cracking Open? You may be overstuffing or skipping the chill step.
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Falling Apart? Let shells rest for 5–10 minutes after smoking—this helps the juices settle and prevents tearing.
Pro Tip: Rotate the shells halfway through smoking if your grill has hot spots for even cooking.
FAQs
Do you boil the manicotti shells first?
No need! The pasta softens as it smokes—boiling them first will make them too soft and likely to tear.
Can I use a grill instead of a smoker?
Absolutely. Set your grill up for indirect heat, and use wood chips in a smoker box or foil pouch to create smoke.
How long should I marinate them before smoking?
At least 4 hours, but overnight is ideal to help soften the pasta and let flavors meld.
What meat is best for the filling?
You can’t go wrong with ground beef, sausage, or even a combo of the two. Just make sure it’s well-seasoned.
Can I make them ahead for a party?
Definitely! Prep and chill the night before. Then smoke just before serving for fresh, hot results.
Smoked Shotgun Shells
Equipment
- Smoker or pellet grill (Traeger, Pit Boss, etc.)
- Meat thermometer
- Wire cooling rack
- Mixing bowl
- Tray or baking sheet
- Toothpicks (optional)
Ingredients
- 12 uncooked manicotti shells
- 1 lb ground beef or sausage
- 1 cup shredded cheddar cheese
- ½ cup cream cheese optional
- 1 jalapeño finely diced (optional)
- 1 tbsp BBQ seasoning or rub
- 24 slices thick-cut bacon
- ½ cup BBQ sauce for glazing
Instructions
- Mix the Filling: In a bowl, combine ground meat, shredded cheese, cream cheese (if using), jalapeño, and seasoning.
- Stuff the Shells: Carefully fill each dry manicotti shell with the meat mixture.
- Wrap with Bacon: Wrap each shell tightly in 2 slices of bacon, overlapping to fully cover the pasta.
- Chill (Optional): Place on a tray and refrigerate for at least 4 hours or overnight.
- Preheat Smoker: Heat smoker to 250–275°F and set up for indirect heat.
- Smoke: Place shells on a wire rack and smoke for 90–120 minutes, until bacon is crisp and internal meat temp reaches 160°F.
- Glaze: In the last 15 minutes, brush BBQ sauce over the bacon for a sticky finish.
- Optional Crisping: Broil or sear for 1–2 minutes if you want crispier bacon.
- Rest & Serve: Let rest for 5 minutes before serving.
Notes
- For extra flavor, marinate stuffed shells overnight.
- Use a piping bag or ziplock to stuff manicotti easily.
- Ground beef, pork, or spicy sausage all work well.
- Thick-cut bacon is best for wrapping and holding shape.
- Don’t skip chilling if you want perfectly softened pasta.
Nutrition
Final Thoughts: Why Smoked Shotgun Shells Deserve a Spot on Your Grill
Whether you’re a seasoned pitmaster or just fired up your first pellet grill, Smoked Shotgun Shells are a guaranteed crowd-pleaser. With their crispy bacon exterior, smoky flavor, and cheesy, meaty center, they’re everything you love about BBQ—wrapped up in one epic bite.
They’re also wildly flexible. From spicy jalapeño fillings to sweet-and-savory brown sugar bacon, you can get creative and customize them to your crowd’s taste. And with the prep-ahead option, they’re perfect for parties, tailgates, or make-ahead BBQ feasts.
So if you’re looking to impress at your next cookout or want a fun twist on traditional smoked fare, give these viral beauties a try. They’re bold, indulgent, and totally unforgettable.
Now it’s your turn—fire up that smoker and show off your own take on smoked shotgun shells. Your backyard BBQ game will never be the same.
