Description

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.

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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Instructions

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.