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Smoked Shotgun Shells Bacon

Ready to fire up your smoker for a treat that’s as bold as a 4th of July fireworks display? These Smoked Shotgun Shells Bacon are the ultimate BBQ appetizer! Packed with ground beef, spicy Italian sausage, creamy cheese, and zesty jalapeño, stuffed into manicotti shells, wrapped in crispy bacon, and slathered with barbecue sauce, they’re a flavor explosion. Inspired by the sizzling Cinco de Mayo Special Smoked Shotgun Shells from FogoCharcoal.com, this recipe is perfect for Independence Day, game days, or any backyard bash. Kids can help mix or wrap bacon, making it a fun family project. Let’s get smoking!

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Overview: Why These Shells Shine

What makes Smoked Shotgun Shells Bacon so special? They’re a hearty, smoky appetizer with a perfect blend of meaty, cheesy, and spicy flavors, all wrapped in crispy bacon. Here’s why you’ll love them:

Time Requirement: About 30 minutes active prep, 2 hours smoking.
Difficulty Level: Easy! Simple mixing, stuffing, and smoking, great for beginners with a smoker.
Why It’s Awesome: They’re bold, make-ahead friendly, and can be dressed up with patriotic dips for 4th of July.

These bacon-wrapped shells are ideal for tailgates, patriotic parties, or any time you want a conversation-starting snack. Let’s check out the ingredients!

Essential Ingredients

A batch of Smoked Shotgun Shells Bacon needs simple ingredients for about 16-24 shells (depending on stuffing). Here’s what you’ll need:

Pasta Shells:
- 16 oz manicotti shells (two 8-oz boxes)
- Why it matters: Holds the meaty filling; stays firm when smoked.
- Substitutions: Use cannell shells (smooth, no ridges). Use lasagna noodles for easier stuffing (roll tightly).
Meat Mixture:
- 1.5 lbs ground beef
- 1 lb hot Italian sausage
- 1 medium onion, finely diced
- 1 jalapeño, finely diced (seeds removed for milder flavor)
- 2 cups sharp cheddar cheese, shredded*
- 6 oz cream cheese, softened
- Why it matters: Beef and sausage add savory richness; jalapeño brings heat; cheeses create gooey texture.
- Substitutions: Use ground turkey or chorizo for beef/sausage. Swap jalapeño for pickled jalapeños or omit for mild. Use pepper jack, mozzarella, or colby jack for cheddar.
Seasonings:
- 2 tsp Slap Ya Mama seasoning
- 2 tsp garlic powder
- 2 tsp black pepper
- 1 tsp red pepper flakes
- Why it matters: Adds spicy, bold flavor to complement the meat.
- Substitutions: Use Cajun seasoning or your favorite BBQ rub for Slap Ya Mama. Adjust red pepper flakes for heat.
Other:
- ⅓ cup barbecue sauce (for filling)
- 32 oz bacon (two 16-oz packages, thin-cut preferred)
- Additional barbecue sauce for coating
- Why it matters: BBQ sauce adds tangy sweetness; bacon wraps for smoky crispiness.
- Substitutions: Use sweet, spicy, or low-sugar BBQ sauce. Swap bacon for turkey bacon (less fat, less crisp).
Optional Patriotic Add-Ins (for 4th of July):
- Red, white, and blue dipping sauces (e.g., sriracha mayo, ranch, blueberry BBQ)
- Fresh cherry tomatoes (red) and mozzarella balls (white) for garnish
- Why it matters: Creates a festive red, white, and blue presentation.
- Substitutions: Use ketchup (red), sour cream (white), or blue food-colored dip.

Tip: Choose thin-cut bacon for crispier results, as thick-cut may not fully crisp. Use fresh jalapeños for a brighter kick. Have extra bacon handy for larger shells.

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Step-by-Step Instructions

Let’s make these Smoked Shotgun Shells Bacon with these easy steps, inspired by the FogoCharcoal.com video. Follow along with tips to make them perfect!

Step 1: Preheat the Smoker

Set your smoker to 250°F (121°C) with your favorite wood (e.g., hickory, apple, or oak).
- Tip: Soak wood chips for 30 minutes for consistent smoke. Ensure the smoker maintains a steady temperature.

Step 2: Prepare the Filling

In a large bowl, combine 1.5 lbs ground beef, 1 lb hot Italian sausage, 1 diced onion, 1 diced jalapeño, 2 cups shredded cheddar, 6 oz cream cheese, 2 tsp Slap Ya Mama seasoning, 2 tsp garlic powder, 2 tsp black pepper, 1 tsp red pepper flakes, and ⅓ cup barbecue sauce.
Mix thoroughly by hand until well incorporated.
- Tip: Soften cream cheese for easier mixing. Wear gloves when handling jalapeño to avoid irritation.

Step 3: Stuff the Shells

Gently fill 16 oz uncooked manicotti shells with the meat mixture from both ends, ensuring no air pockets.
- Tip: Use a spoon or piping bag to stuff carefully; avoid cracking shells. A chopstick can help push filling through.

Step 4: Wrap with Bacon

Wrap each stuffed shell with 1-2 slices of bacon, covering the ends to prevent leakage.
Secure with toothpicks if needed (remove after smoking).
- Tip: Stretch bacon slightly for full coverage; thin-cut bacon crisps better. Align bacon with the shell’s angled ends for a tight wrap.

Step 5: Coat with BBQ Sauce

Brush additional barbecue sauce over both sides of the bacon-wrapped shells.
Place on a baking sheet while preparing the remaining shells.
- Tip: Use a sweet BBQ sauce (e.g., Sweet Baby Ray’s) to balance the spice. Coat generously to keep pasta moist.

Step 6: Smoke the Shells

Place the shells on the smoker grates or a wire rack.
Smoke at 250°F for 60 minutes.
Flip the shells, baste with more barbecue sauce, and smoke for another 60 minutes or until bacon is crispy and the internal temperature reaches 165°F.
- Tip: Check bacon crispiness; if needed, increase smoker to 300°F for the last 15-20 minutes. Use a meat thermometer for safety.

Step 7: Serve

Remove shells from the smoker and let rest for 5-10 minutes.
Serve immediately, optionally with patriotic dips like ranch (white), sriracha mayo (red), or blueberry BBQ (blue).
- Tip: Cut shells in half for finger-food portions at parties. Garnish with cherry tomatoes and mozzarella for a 4th of July flair.

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Assembly: Building Your Shotgun Shells

Creating Smoked Shotgun Shells Bacon is like loading up flavor-packed firecrackers! Here’s how to make them look amazing:

Stuffed Shells: Fill manicotti with a meaty, cheesy mixture for a hearty base.
Bacon Wrap: Encase in crispy bacon for smoky crunch.
BBQ Glaze: Brush with barbecue sauce for a sticky, tangy finish.
Patriotic Presentation: Serve with red, white, and blue dips or garnishes.
- Presentation Tip: Arrange on a star-shaped platter with small flag picks or red, white, and blue napkins. Scatter cherry tomatoes and mozzarella balls for a festive 4th of July vibe!

Tip: Ensure bacon covers shell ends to keep filling secure and pasta moist. Serve hot for the best texture.

Storage and Make-Ahead Tips

Want to enjoy your Smoked Shotgun Shells Bacon later? Here’s how to keep them fresh:

Storing Leftovers:
- Store in an airtight container in the fridge for 3-4 days.
- Reheat at 325°F in the oven for 20 minutes, adding extra BBQ sauce to re-crisp bacon.
- Note: Best within a few days; avoid refreezing to maintain texture.
Make-Ahead Tips:
- Stuff and wrap shells up to 48 hours ahead; refrigerate covered.
- Brush with BBQ sauce just before smoking to prevent sogginess.
- Freeze uncooked shells (without sauce) for up to 1 month; thaw in fridge before smoking.
- Tip: Prep shells a day ahead for parties. Add patriotic dips just before serving for a fresh, festive look.

These shells are perfect for stress-free BBQ planning!

Recipe Variations

Smoked Shotgun Shells Bacon are super fun to customize! Try these ideas for a 4th of July twist or beyond:

Patriotic Dips: Serve with sriracha mayo (red), ranch (white), and blueberry BBQ (blue) for a flag-inspired spread.
Mild Version: Use mild Italian sausage, omit jalapeño and red pepper flakes.
Chorizo Kick: Swap beef for chorizo and add diced green chiles for a Tex-Mex vibe.
Cheese Swap: Use pepper jack or smoked gouda for a different flavor.
Oven-Baked: Bake at 325°F for 1 hour, flipping halfway, then 350°F for 10-15 minutes to crisp bacon.

Get creative—every version is a smoky delight!

Health Benefits

While Smoked Shotgun Shells Bacon are an indulgent treat, they have some perks when enjoyed in moderation:

Protein-Packed: Beef, sausage, and cheese provide protein for muscle health.
Calcium: Cheddar and cream cheese offer calcium for bones.
Portion Control: Cut into halves for smaller servings at parties.
- Tip: Use leaner beef (90/10) or turkey sausage to reduce fat. Serve with fresh veggies or dips for balance.

Nutrition Info (Per Shell, Approx. 16-24 Servings)

Calories: ~400-450 kcal
Fat: 30-35g (from bacon, beef, sausage, cheese)
Carbohydrates: 10-12g (from pasta, BBQ sauce)
Protein: 20g (from meat, cheese)
Calcium: ~10% daily value (from cheese)

Note: Nutrition varies with bacon type and portion size; use leaner meats for lower fat.

Conclusion

These Smoked Shotgun Shells Bacon are the ultimate smoky appetizer for patriotic celebrations! With their meaty, cheesy filling, crispy bacon wrap, tangy BBQ glaze, and optional red, white, and blue dips, they’re perfect for 4th of July, game days, or any BBQ. Inspired by FogoCharcoal.com’s Cinco de Mayo special, they’re protein-packed, quick to prep, and so fun to customize. Fire up your smoker, get the kids to help wrap bacon, and create these flavor-packed shells. Share your creations in the comments—I’d love to see your patriotic BBQ spread!

Smoked Shotgun Shells Bacon

Author: Alyssa

Print Recipe

Description

Ingredients

Scale

A batch of Smoked Shotgun Shells Bacon needs simple ingredients for about 16-24 shells (depending on stuffing). Here’s what you’ll need:

Pasta Shells:
- 16 oz manicotti shells (two 8-oz boxes)
- Why it matters: Holds the meaty filling; stays firm when smoked.
- Substitutions: Use cannell shells (smooth, no ridges). Use lasagna noodles for easier stuffing (roll tightly).
Meat Mixture:
- 1.5 lbs ground beef
- 1 lb hot Italian sausage
- 1 medium onion, finely diced
- 1 jalapeño, finely diced (seeds removed for milder flavor)
- 2 cups sharp cheddar cheese, shredded*
- 6 oz cream cheese, softened
- Why it matters: Beef and sausage add savory richness; jalapeño brings heat; cheeses create gooey texture.
- Substitutions: Use ground turkey or chorizo for beef/sausage. Swap jalapeño for pickled jalapeños or omit for mild. Use pepper jack, mozzarella, or colby jack for cheddar.
Seasonings:
- 2 tsp Slap Ya Mama seasoning
- 2 tsp garlic powder
- 2 tsp black pepper
- 1 tsp red pepper flakes
- Why it matters: Adds spicy, bold flavor to complement the meat.
- Substitutions: Use Cajun seasoning or your favorite BBQ rub for Slap Ya Mama. Adjust red pepper flakes for heat.
Other:
- ⅓ cup barbecue sauce (for filling)
- 32 oz bacon (two 16-oz packages, thin-cut preferred)
- Additional barbecue sauce for coating
- Why it matters: BBQ sauce adds tangy sweetness; bacon wraps for smoky crispiness.
- Substitutions: Use sweet, spicy, or low-sugar BBQ sauce. Swap bacon for turkey bacon (less fat, less crisp).
Optional Patriotic Add-Ins (for 4th of July):
- Red, white, and blue dipping sauces (e.g., sriracha mayo, ranch, blueberry BBQ)
- Fresh cherry tomatoes (red) and mozzarella balls (white) for garnish
- Why it matters: Creates a festive red, white, and blue presentation.
- Substitutions: Use ketchup (red), sour cream (white), or blue food-colored dip.

Tip: Choose thin-cut bacon for crispier results, as thick-cut may not fully crisp. Use fresh jalapeños for a brighter kick. Have extra bacon handy for larger shells.

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