Smoked Shotgun Shells
Bacon-wrapped manicotti shells stuffed with seasoned ground beef, cream cheese, and cheddar — smoked low and slow at 250°F until the bacon crisps and the filling hits 165°F. A crowd-pleasing BBQ appetizer that's easier than it looks.
Equipment
- Smoker or pellet grill set to 250°F
- Instant-read meat thermometer to check 165°F internal temp
- Sheet pan for fridge rest
- Zip-lock bag cut corner for DIY piping bag (optional)
Ingredients
For the Filling
- 1 lb ground beef (80/20) or hot Italian sausage or a mix of both
- 4 oz cream cheese softened to room temperature
- 1 cup shredded cheddar or Monterey Jack cheese sharp cheddar recommended
- 2 tbsp BBQ rub your favorite blend
- 1 jalapeño diced, optional
For the Shells
- 12 manicotti shells dry, uncooked — not oven-ready
- 1 lb thin-cut bacon thin-cut only — not thick-cut
- 1/2 cup BBQ sauce sweet-style recommended
Instructions
- Mix the ground beef or sausage, softened cream cheese, shredded cheese, BBQ rub, and any optional mix-ins (jalapeño, onion) in a large bowl. Mix thoroughly with your hands until everything is evenly combined.
- Spoon the filling into a zip-lock bag and cut one corner off to use as a piping bag. Pipe filling into each manicotti shell from both ends, packing firmly to eliminate air pockets.
- Wrap each stuffed shell in thin-cut bacon in a tight spiral, pulling slightly to stretch the bacon. Start at one end and work toward the other, overlapping each pass. Tuck both ends under the shell. Ensure total bacon coverage — exposed pasta won't soften.
- Place wrapped shells on a sheet pan in a single layer. Cover with plastic wrap and refrigerate for at least 4–6 hours, or overnight. This step is mandatory — the pasta absorbs moisture from the filling and softens during this rest.
- Preheat your smoker to 250°F. Add hickory, apple, cherry, or pecan wood. Let the smoker stabilize before loading the shells.
- Place the shells directly on the grill grates — not on a pan or foil. Smoke for 90 minutes to 2 hours until the internal temperature of the meat filling reaches 165°F, measured with an instant-read thermometer inserted through the end of the shell.
- When the internal temp reaches 155–160°F, brush generously with BBQ sauce on all sides. Raise smoker to 275–300°F and smoke for another 10–15 minutes until the sauce sets and bacon crisps. Shells are done at 165°F internal.
- Remove from the smoker and rest for 5 minutes. Serve as-is or with ranch, blue cheese, or Caesar dressing for dipping.
Notes
Crunchy shells? Either the fridge rest was too short (less than 4 hours) or pasta was exposed (not fully covered by bacon). Fix: overnight rest + total bacon coverage.
Wood pairing: Hickory for bold BBQ flavor; apple or cherry for a lighter, sweeter smoke that lets the filling shine.
Make-ahead: Assemble up to 48 hours ahead and refrigerate. Smoke from frozen by adding 30–45 extra minutes.