Smoked Shotgun Shells – Bacon-Wrapped Cheesy Meat-Stuffed Pasta Bombs

Juicy. Cheesy. Smoky. Spicy. Crunchy. These shotgun shells are the ultimate BBQ showstopper. Imagine seasoned ground meat mixed with cheese, stuffed into pasta tubes, wrapped in smoky bacon, slow-cooked to perfection, and glazed with BBQ sauce until they’re sweet, sticky, and crispy.

This recipe isn’t just food. It’s a conversation starter, crowd-pleaser, and mouth-watering centerpiece.

 Ingredients (Makes About 28 Shells)

For the Filling:

• 1.5 lbs ground beef (80/20 blend for flavor)
• 1 lb hot Italian sausage (casing removed)
• 1 cup shredded cheddar cheese
• 1 cup shredded mozzarella cheese
• ½ cup cream cheese (softened)
• ¼ cup diced pickled jalapeños (optional for heat)
• ¼ cup chopped green onions
• 1 tsp black pepper
• 1 tsp smoked paprika
• ½ tsp ground cumin
• 2 tbsp BBQ sauce (adds moisture + flavor)

For the Shells:

• 28 dry manicotti or cannelloni pasta shells (uncooked)
• 28 slices of smoked bacon (you may need more if your bacon is thin)

Optional Topping:

• BBQ sauce for glazing
• A light sprinkle of brown sugar + chili powder for extra caramelization

Instructions

Step 1: Prepare the Filling

In a large mixing bowl, combine the ground beef, sausage, cheeses, jalapeños, green onion, spices, and BBQ sauce. Mix well by hand until fully incorporated.
Pro tip: Chill the mixture for 30–60 minutes so it’s easier to stuff and shape.

Step 2: Stuff the Pasta Shells

Using your hands or a piping bag, carefully fill each dry pasta shell with the meat mixture. Stuff it full but avoid breaking the pasta.
Do NOT pre-cook the pasta. The shells will cook slowly and soak up moisture from the meat while smoking or baking.

Step 3: Wrap in Bacon

Wrap each stuffed shell tightly with a slice of bacon. If needed, use a second slice to cover the ends or secure with toothpicks.
Make sure the bacon is snug but not overlapping too thickly. It needs to crisp up.

Step 4: Rest in the Fridge

Place the wrapped shells on a wire rack over a tray and refrigerate them for at least 4 hours or overnight.
This helps the pasta soften a bit and keeps everything intact while cooking.

 Cooking Methods

Method 1: Smoking (Best Flavor)

• Preheat your smoker to 250°F (120°C).
• Place the shells directly on the rack.
• Smoke for 2 to 2.5 hours, turning if needed.
• In the last 20 minutes, brush with BBQ sauce and sprinkle brown sugar/chili powder if desired.

Method 2: Oven (If No Smoker)

• Preheat oven to 350°F (175°C).
• Bake on a wire rack over a baking sheet for 50–60 minutes.
• Broil the last 3–5 minutes for extra crispiness.
• Glaze with BBQ sauce near the end for that sticky finish.

Tips & Tricks

• Pasta shells: Dry manicotti is key. It holds shape and softens while cooking.
• Bacon thickness: Medium-thick is best. Too thick won’t crisp, too thin may break.
• Flavor variations: Add cooked rice, chorizo, or different cheeses for custom twists.
• Serving idea: Pair with ranch dip, hot sauce, or a cool coleslaw on the side.
• Meal prep: You can freeze uncooked shells. Just thaw before cooking.