The Comfort Spoon

 

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Smoked Shotgun Shells: Your New BBQ Secret Weapon

Hey there, friend! Let’s talk about that moment when you want to bring something to the party that doesn’t just sit politely on the table. I’m talking about the dish that makes people’s eyes go wide, the one that sparks a chorus of “What IS that?” and “Who made these?!” before it’s instantly devoured. If you’re nodding along, then you, my friend, are ready for the glorious, the irresistible, the downright show-stopping Smoked Shotgun Shell.

Imagine this: a tender manicotti shell, stuffed to the brim with a perfectly seasoned, spicy, and cheesy meat blend, then lovingly swaddled in a crisp, smoky blanket of bacon. It’s smoked low and slow until the bacon is crackly, the pasta is tender, and the filling is juicy and bursting with flavor. We’re not just making an appetizer here; we’re crafting a full-blown experience. These bacon-wrapped BBQ pasta bombs are the ultimate fusion of backyard BBQ indulgence and comforting, cheesy pasta goodness.

Now, I see that look. You might be thinking, “Anna, manicotti on the smoker? Is that even a thing?” Trust me, it’s not just a thing—it’s a revelation. The magic happens as the pasta slowly soaks up all that incredible smoky flavor while staying wonderfully tender on the inside. The result is a bite that’s smoky, meaty, cheesy, and has just the right amount of texture from that glorious bacon wrap. They’re fun to make, incredibly satisfying to serve, and guaranteed to turn any ordinary Tuesday or epic game day into a memorable feast. So, grab your favorite BBQ sauce and let’s make some kitchen magic together!

The Party That Started It All

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I’ll never forget the first time I encountered these. It was at a chaotic, wonderful, and incredibly loud family football watch party at my cousin Mike’s house. The air was crisp, the game was on, and his backyard smoker was billowing with that unmistakable scent of hickory and promise. Amidst the trays of wings and burgers, he brought out this platter of these bizarre, bacon-clad tubes. They looked like something a mad scientist of meat would dream up.

I was skeptical, I’ll admit it. But one bite? Oh, one bite was all it took. There was a collective pause around the table, followed by a wave of pure, unadulterated food joy. The crunch of the bacon gave way to the tender pasta and the explosive, savory filling. They were gone in about 90 seconds flat. I knew right then I had to master these for my own family. I’ve tweaked and tested the recipe over countless gatherings since, and it’s become the most-requested dish I make. It’s more than a recipe; it’s a ticket to being the undisputed hero of any potluck.

Gathering Your Flavor Arsenal

Here’s everything you’ll need to create these smoky masterpieces. Don’t be shy about making swaps based on what you have—cooking is all about making it your own!

• 2 boxes (8 oz each) uncooked manicotti pasta shells: You’ll want the classic, large tubular shells. Don’t pre-cook them! The magic of this recipe is that the dry pasta softens perfectly during the long, slow smoke, soaking up all the smoky flavor and meaty juices.
• 1½ lbs ground beef (80/20 blend is perfect): A little fat is our friend here—it keeps the filling incredibly moist and flavorful as it cooks. You can use leaner beef, but the result might be a tad drier.
• 1 lb hot Italian sausage: This is our secret weapon for a flavor and spice kick! If you’re sensitive to heat, mild Italian sausage works beautifully too. The fennel and herbs in the sausage add a wonderful depth.
• 1½ cups shredded cheddar or mozzarella cheese: I’m a cheddar girl for that sharp tang, but mozzarella gives you that glorious, epic cheese pull we all love. A blend of both is absolutely heavenly.
• ½ cup BBQ sauce, plus extra for glazing: Use your absolute favorite brand here! Whether you like a sweet, smoky, or vinegar-based sauce, it will shine through. This is the glue that binds our filling and adds a touch of sweetness.
• 1 tsp garlic powder & 1 tsp onion powder: These pantry powerhouses build a solid, savory foundation for our meat filling. They distribute flavor more evenly than fresh in this case.
• 1 tsp smoked paprika: We’re doubling down on the smokiness! This adds a beautiful red color and a deep, warm flavor that complements the actual smoking process perfectly.
• Salt and pepper to taste: Always season as you go! I start with a teaspoon of kosher salt and a half teaspoon of black pepper and adjust from there.
• 20–24 slices thin-cut bacon: Thin-cut is crucial! It gets beautifully crisp in the smoker. Thick-cut bacon can remain chewy and won’t wrap as easily. Trust me on this one.
• Optional garnish: chopped fresh green onions: A sprinkle of these at the end adds a fresh, sharp pop of color and flavor that cuts through the richness beautifully.

Let’s Build Some Flavor Bombs: A Step-by-Step Guide

Ready to get your hands a little dirty? This process is as fun as it is rewarding. Let’s break it down, step by delicious step.

1. Prep the Filling: In a large mixing bowl, add your ground beef, Italian sausage (squeeze it right out of its casing), shredded cheese, ½ cup of BBQ sauce, garlic powder, onion powder, smoked paprika, salt, and pepper. Now, roll up your sleeves and dive in with your hands! Mix everything until it’s just fully combined. Chef’s Hack: Don’t overwork the meat, or it can become tough. Just mix it until you no longer see streaks of individual ingredients.
2. The Great Shell Stuffing: Now, grab your uncooked manicotti shells and your meat mixture. The easiest way to stuff these is with your hands! Take a small handful of the meat mixture and gently press it into the shell, working it through from one end to the other. Pro Tip: Leave a tiny bit of room for expansion—the pasta and meat will puff up a little as they cook, and we don’t want any explosive blowouts! If you have a piping bag, you can use that, but I find hands are the most intuitive tools.
3. The Bacon Blanket: Lay out a slice of your thin-cut bacon. Take one stuffed shell and place it at one end. Roll it up tightly, ensuring the bacon overlaps itself to fully encase the pasta. The bacon’s own fat will act as glue and hold it in place as it cooks. If a shell is particularly plump, don’t hesitate to use a second slice of bacon. There’s no such thing as too much bacon here!
4. The Patience-Paying Chill: This might be the hardest step, but it’s a game-changer. Arrange your bacon-wrapped beauties on a tray, cover them, and let them rest in the fridge for at least 4-6 hours, or even overnight. Why? This resting time allows the dry pasta to slowly absorb moisture from the meat and bacon, softening up so it cooks through perfectly on the smoker without becoming mushy. It’s the secret to the perfect pasta texture!
5. Smoke ‘Em Low and Slow: Fire up your smoker (or grill set up for indirect heat) to a steady 250°F (120°C). I love using hickory or applewood for this—hickory for a strong, classic BBQ punch, or applewood for a sweeter, milder smoke. Place the shotgun shells directly on the grill grates. Let them smoke for about 2 to 2.5 hours. You’re looking for the bacon to be nicely crisped and the internal temperature of the meat filling to hit a safe 165°F.
6. The Glorious Glaze: During the last 10-15 minutes of cooking, pull out your shotgun shells and give them a generous brush with your remaining BBQ sauce. This final layer will caramelize and set into a sticky, finger-licking-good glaze that takes them over the top. Pop them back on the smoker to let that glaze work its magic.
7. The Grand Finale: Carefully remove them from the smoker and let them rest for about 5-10 minutes. They will be molten-lava hot inside! This rest allows the juices to redistribute. Then, transfer them to a platter, sprinkle with those vibrant green onions, and get ready for your standing ovation.

How to Serve These Showstoppers

Presentation is part of the fun! I love serving these on a big, rustic wooden board or a large platter. Scatter some extra green onions over the top for a fresh, colorful contrast to the deep, mahogany color of the bacon. Keep a little extra warm BBQ sauce on the side for dipping, because why not? They are a complete meal in themselves, but they pair fantastically with a simple, crisp coleslaw or a bright, tangy potato salad to balance out the richness. Don’t forget napkins—these are meant to be eaten with your hands!

Make It Your Own: Fun Recipe Twists

The basic recipe is a masterpiece, but feel free to play with the flavors!

• Spicy Fiesta: Swap the Italian sausage for spicy chorizo and use a pepper jack cheese. Add a teaspoon of cumin to the meat mix for a Tex-Mex twist.
• Pizza Party: Use a mix of ground beef and pepperoni, swap the BBQ sauce for pizza sauce, and use mozzarella cheese. Finish with a brush of garlic butter instead of BBQ glaze.
• Jalapeño Popper: Mix ½ cup of finely diced jalapeños and 4 oz of softened cream cheese into the meat filling. The creamy, spicy combo is insane.
• Turkey Swap: For a leaner option, use ground turkey and chicken apple sausage. The flavors are still fantastic!

Anna’s Kitchen Corner: Notes from My Counter

This recipe has truly evolved in my kitchen. The first time I made them, I was so impatient I skipped the chill time. Big mistake! The pasta was still crunchy in the middle. I learned that the chill is non-negotiable for that perfect al dente texture. Now, I make them the night before a party—it makes the day-of a total breeze.

Another funny kitchen fail: I once used thick-cut bacon because it was on sale. Let’s just say I ended up with beautifully cooked filling inside of pasta that was still a bit tough, wrapped in bacon that was somehow both burnt and rubbery. We live and we learn! Thin-cut bacon for the win, always. These little bombs are a labor of love, but I promise you, every minute is worth it when you see the smiles they bring.

Your Questions, Answered!

Q: Can I make these in the oven instead of a smoker?
A: Absolutely! While you’ll miss the deep smoky flavor, they will still be delicious. Preheat your oven to 375°F (190°C). Place the chilled, bacon-wrapped shells on a wire rack set over a baking sheet (this helps the bacon crisp all around). Bake for about 45-55 minutes, or until the bacon is crisp and the internal temperature reaches 165°F. Brush with BBQ sauce and pop back in for 5-10 minutes to set the glaze.

Q: My bacon isn’t getting crispy. What did I do wrong?
A: This is a common issue! First, double-check that you’re using thin-cut bacon. Second, make sure your smoker temperature is accurate—if it’s running too low, the bacon will render its fat slowly and can end up chewy. If you’re near the end of cook time and the bacon still looks pale and flabby, don’t be afraid to crank the heat up to about 325°F for the last 10-15 minutes to help it crisp up.

Q: Can I prepare these ahead of time and freeze them?
A: You sure can! They are a fantastic make-ahead appetizer. After you wrap them in bacon and complete the 4-6 hour chill, you can transfer them to a freezer-safe bag or container. They’ll keep for up to 3 months. When you’re ready, smoke them straight from the freezer—just add an extra 30-45 minutes to the cooking time, and always use a meat thermometer to ensure they hit 165°F internally.

Q: Help! My meat filling is bursting out of the pasta while cooking.
A: No worries, it happens! This usually means the shells were just a tad overstuffed. The meat and pasta expand a bit as they cook. Next time, just leave a little more room in the shell. For now, just embrace the rustic, “exploded” look—I promise they will still taste incredible!

Nutritional Information*

*Please note: This is an estimated nutritional breakdown. Values can vary based on specific ingredients used.

Per Serving (based on 8 servings): Calories: ~550 | Protein: 30g | Carbohydrates: 12g | Fat: 42g | Fiber: 1g

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Final Thoughts

At the end of the day, these Smoked Shotgun Shells aren’t just an appetizer—they’re an experience. They’re the kind of dish that brings people circling around the table, pointing, laughing, grabbing “just one more,” and telling stories between bites. And honestly? That’s my favorite kind of food. The food that makes a moment feel a little bigger, a little louder, a little more joyful.

Every time I make these, I’m reminded why they’ve become such a legendary staple in my family. They’re bold, smoky, cheesy, over-the-top in the best possible way, and they deliver that magical combination of crunch, tenderness, and melt-in-your-mouth flavor that keeps everyone talking long after the platter is empty. They’re one of those recipes that turns a casual hangout into a full-blown memory.

So the next time you want to show up with something unforgettable—something that guarantees you’ll be the hero of the potluck or backyard gathering—bring a tray of these beauties. Take a little time the night before, trust the process, and let your smoker work its slow, smoky magic. Then just stand back and enjoy the chorus of happy chaos that follows.