Smoked Shotgun Shells – Insanely Flavorful And Easy To Make

Before we get into the juicy details, let me tell you how these smoked shotgun shells first showed up on my menu. One summer night here in Asheville, a neighbor brought over a tray of manicotti tubes stuffed with meat and wrapped in bacon—and said, “Try this.” I didn’t ask questions. I took a bite. That shell was smoky, savory, with just the right bite of spice and a smoky crust that made it unforgettable. Next thing I knew, I was making batch after batch for my supper club. This dish became a staple, especially when paired with fun summer sides like corn ribs or my always-requested smoked cream cheese.

In this article, you’ll learn exactly how to make smoked shotgun shells with foolproof tips, clever ingredient swaps, and tricks for that perfect smoke ring. We’ll also answer common questions like how to reheat them, what makes them “BBQ shotgun shells,” and even touch on a few spicy myths. Whether you’re smoking on a Traeger, pellet grill, or your old faithful offset, this one’s going to impress.

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What Are Smoked Shotgun Shells?

Smoked shotgun shells are manicotti pasta tubes stuffed with a seasoned meat mixture, wrapped in bacon, and slow-smoked until every bite is juicy, smoky, and slightly crispy on the outside. The magic lies in the contrast—the chew of the pasta, the smoky fat from the bacon, and the hearty, savory stuffing inside. They’re called “shotgun shells” because the uncooked manicotti tubes resemble oversized shell casings, and once they’re cooked, they deliver flavor that hits like a blast—in the best way.

I like to fill mine with a blend of spicy Italian sausage, cheddar cheese, and a dash of chopped jalapeños. Others swear by a brisket mix or even chorizo. The beauty is, once you master the method, the fillings are entirely up to you. You’ll also want to refrigerate the assembled shells before smoking them—this softens the pasta and helps the flavors marry.

Why They’re a Smoked Shotgun Shells Favorite

There’s something deeply satisfying about smoking a tray of these. The bacon crisps just enough to hold its shape, while the stuffing steams and cooks inside the pasta, locking in moisture. These are ideal for tailgates, game days, or backyard BBQs. They sit proudly alongside smash burger tacos and creamy cowboy butter as the kind of bold bites folks remember.

Need a quick prep tip? Use a piping bag or zip-top bag with the corner cut off to fill the tubes—your hands (and sanity) will thank you. As for the smoker, low and slow at 250°F works best, and you’ll want about 90 minutes of cook time.

How to Make Smoked Shotgun Shells

Simple Ingredients, Big BBQ Flavor

The best part of smoked shotgun shells? You don’t need fancy ingredients. You probably have most of these in your fridge already. Here’s what you’ll need for a classic batch:

Ingredients:

• 1 box of manicotti shells (uncooked)
• 1 lb ground beef or spicy Italian sausage
• 1 cup shredded cheddar (or pepper jack for heat)
• 2 tablespoons diced jalapeños (optional, but adds kick)
• ½ teaspoon garlic powder
• ½ teaspoon smoked paprika
• Salt and pepper to taste
• 1 pack of thin-cut bacon (you’ll need about 12–14 strips)
• Your favorite BBQ rub (about 2 tablespoons)
• BBQ sauce for glazing

Want to add a creamy twist? Fold in some softened cream cheese or shredded smoked gouda—especially if you’re pairing this with my smoked cream cheese board for a full flavor spread.

Step-by-Step Instructions

1. Make the Filling: In a mixing bowl, combine the ground meat, cheese, jalapeños, garlic powder, paprika, salt, and pepper. Mix until just combined—don’t overwork it.
2. Stuff the Shells: Use a piping bag or your hands to fill each uncooked manicotti tube with the meat mixture. Be gentle—you want them packed but not bursting.
3. Wrap in Bacon: Wrap each stuffed shell in a slice of bacon, overlapping slightly so the bacon seals the pasta. If needed, secure ends with a toothpick.
4. Rub & Rest: Dust each bacon-wrapped shell with your favorite BBQ rub. Place them on a tray, cover, and refrigerate for 4 hours (or overnight). This softens the pasta and lets flavors meld.
5. Smoke: Preheat your smoker to 250°F. Arrange the shells on the grates, seam-side down. Smoke for 60 minutes.
6. Glaze: After 1 hour, brush with BBQ sauce and continue smoking for another 30 minutes until the bacon is crisp and internal temp hits 160°F.

Smoking Tips and Flavor Variations for Shotgun Shells

Smoke It Right: Temperature, Wood, and Timing

Low and slow is the golden rule when it comes to smoked shotgun shells. Keep your smoker steady at 250°F for that perfect balance between bacon crispness and tender, cooked-through stuffing. No need to parboil the manicotti—the extended chill time in the fridge allows the uncooked pasta to soften just right while it smokes.

Wood choice matters too. Hickory or oak adds boldness, while cherry or applewood gives a slightly sweet finish that balances well with spicy meat fillings. I like to smoke mine on a wire rack or grill mat, which makes cleanup easy and prevents shells from sticking.

If you’re working with a pellet grill like a Traeger, consider adding a smoker tube filled with wood chips to boost the smoky flavor, especially during the first 30 minutes. Just like when I’m prepping cowboy butter or smoking cream cheese, I always keep an eye on smoke consistency.

Flavor Twists You’ll Love

Once you’ve mastered the classic version, it’s time to get creative. Here are a few favorite twists my supper club raves about:

• Tex-Mex Style: Swap cheddar for pepper jack and mix in taco seasoning. Serve with sour cream and salsa.
• Breakfast Bomb: Fill with scrambled eggs, breakfast sausage, and cheddar. Smoke, then drizzle with maple syrup before serving.
• BBQ Brisket Shells: Use chopped brisket and smoked gouda, then glaze with a bold, molasses-rich BBQ sauce.
• Buffalo Ranch: Combine ground chicken, cream cheese, buffalo sauce, and ranch seasoning—crisp, spicy, and full of tang.

No matter your twist, presentation matters. Serve on a wooden board with picks, dipping sauces, or right alongside smash burger tacos for the ultimate BBQ finger food spread.

Storage, Reheating, and FAQs About Smoked Shotgun Shells

How to Store and Reheat Smoked Shotgun Shells

Smoked shotgun shells are a gift that keeps on giving—if you store them properly. After cooling completely, place leftovers in an airtight container and refrigerate for up to 4 days. You can also freeze them, wrapped individually in foil and placed in a zip-top bag, for up to 3 months.

Reheating them the right way makes all the difference. To keep the bacon crispy and the center warm:

• Oven method (recommended): Preheat to 350°F. Place shells on a wire rack over a baking sheet and cover loosely with foil. Bake for 12–15 minutes until warmed through.
• Smoker method (for purists): Re-smoke at 250°F for about 20 minutes.
• Avoid the microwave—it’ll zap the texture and turn bacon rubbery. You want that smoky, crispy bite just like when they came off the smoker during your weekend BBQ alongside corn ribs or smoked cream cheese.

FAQ Time: Smoked Shotgun Shells Edition

Conclusion

From the moment I first bit into one at a neighborhood cookout to the dozens I’ve smoked for supper club nights here in Asheville, smoked shotgun shells have become one of my go-to BBQ showstoppers. They’re crunchy, smoky, stuffed with flavor, and surprisingly simple to make. Whether you’re trying them as-is or adding your own twist, I hope they become a favorite in your backyard, too.

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