Smoked Shotgun Shells: The Ultimate Bacon-Wrapped Manicotti BBQ Appetizer

Smoked shotgun shells are a truly unique and incredibly satisfying barbecue appetizer. Imagine perfectly cooked manicotti pasta tubes, generously stuffed with a savory mixture of Italian sausage and creamy Mozzarella cheese, then meticulously wrapped in crispy bacon, and finally, finished with a delightful blend of BBQ rub and tangy barbecue sauce. This dish offers an explosion of flavors and textures that will tantalize your taste buds and impress your guests at any gathering.

The idea of “Smoked Shotgun Shells” first came to me through my sister-in-law, who enthusiastically described this new and fun barbecue treat. Initially, I admit I was a little skeptical – pasta, sausage, cheese, and bacon all smoked together? It sounded a bit unconventional. However, the more she elaborated, the more intrigued I became. As avid fans of creative finger foods, especially those that involve firing up the smoker, my interest was immediately piqued.

The combination of Italian sausage, creamy cheese, sturdy manicotti, crispy bacon, and smoky barbecue sauce, all brought to life on the smoker, promised something truly special. It wasn’t long before I decided to give this intriguing creation a try. And let me tell you, the result was nothing short of spectacular! These smoked shotgun shells quickly became a staple in our barbecue repertoire, a delicious and surprisingly simple appetizer that consistently earns rave reviews.

Why This Smoked Shotgun Shells Recipe Works

This recipe isn’t just a novelty; it’s a culinary masterpiece that consistently delivers on flavor and satisfaction. Here’s why smoked shotgun shells are destined to become your new favorite barbecue appetizer:

• Perfect for Parties: This recipe yields a generous amount of flavorful appetizer bites, making it ideal for feeding a crowd at your next cookout, game day party, or family gathering. Each shell is a self-contained explosion of taste.
• Layers of Flavor: The interplay between the smoky bacon, rich Italian sausage, creamy cheese, and sweet and spicy barbecue sauce is simply divine. Each ingredient contributes a distinct layer, resulting in a complex yet harmonious flavor profile that keeps you coming back for more.
• Excellent Texture: The bacon crisps up beautifully on the smoker, providing a delightful crunch that contrasts with the tender, flavor-infused pasta shell. The manicotti pasta, far from being mushy, retains a pleasant al dente texture thanks to our unique preparation method, holding up perfectly to the hearty filling and smoky cooking process.
• Simple Ingredients: You won’t need to hunt for obscure items. This recipe calls for readily available ingredients that you likely already have in your pantry or can easily find at any local grocery store. It’s an accessible dish for any home cook.
• Creative Versatility: While delicious as is, this recipe is incredibly adaptable. You can easily get creative and experiment with different fillings, cheeses, rubs, and sauces to customize it to your personal preferences, making it truly your own signature dish.
• Efficient Cook Time: The active cooking time on the smoker is surprisingly quick, especially considering the depth of flavor achieved. This means you can prepare these shells ahead of time, pop them on the smoker, and have a fantastic appetizer ready in under two hours, allowing you more time to enjoy your gathering.

In essence, smoked shotgun shells offer a combination of irresistible flavors, satisfying textures, ease of preparation, and impressive versatility, making them a consistently winning recipe for any occasion. They are a guaranteed crowd-pleaser that will elevate your barbecue game!

Tips and Flavorful Variations for Your Shotgun Shells

While the classic Italian sausage, cream cheese, and mozzarella combination is undoubtedly delicious, this smoked shotgun shells recipe is a fantastic canvas for culinary creativity. Don’t hesitate to personalize it and make it your own! Here are some exciting tips and variations to inspire your next batch:

• Experiment with Different Sausages:
  • For a breakfast-inspired twist, try using hot or mild breakfast sausage. This pairs wonderfully with a sharp cheddar cheese.
  • For a richer flavor and different texture, consider a 50/50 mix of ground pork and ground beef. This gives you a more robust, meaty filling.
  • Looking for a bit of heat? Substitute the Italian sausage with a spicy chorizo or a hot Italian sausage for an extra kick.
• Cheese Combinations:
  • Instead of mozzarella, try other fantastic melting cheeses like Monterey Jack cheese, Pepper Jack for some spice, or a smoky gouda for added depth.
  • A blend of cheddar and Monterey Jack (often sold as “Colby Jack”) can also provide a great balance of flavor and meltiness.
  • For an even creamier filling, increase the cream cheese slightly or add a touch of ricotta cheese to the mixture.
• Add Fresh Ingredients:
  • Finely diced jalapeños (seeds removed for less heat), minced green onions, and fresh cilantro mixed into the meat and cheese combination would add incredible freshness and a Tex-Mex flair.
  • Sautéed diced bell peppers and onions could also be incorporated for more vegetable goodness and a hint of sweetness.
  • A touch of minced garlic or garlic powder can always enhance the savory notes.
• Rub and Sauce Exploration:
  • The choice of BBQ rub can dramatically change the flavor profile. Experiment with different sweet, savory, or spicy rubs. A Memphis-style rub will offer a different experience than a Kansas City-style rub.
  • Similarly, play around with various barbecue sauces. A sweet and smoky sauce will yield a different result than a vinegar-based or mustard-based sauce. You can even try a spicier sauce like a bourbon chipotle or a Carolina gold for a unique finish.
• Creative Toppings:
  • Before serving, sprinkle with chopped fresh parsley or chives for a pop of color and herbaceous note.
  • A drizzle of ranch dressing or a dollop of sour cream could complement spicier variations.

The beauty of this recipe lies in its versatility. Don’t be afraid to put your own culinary flair into it and make these smoked shotgun shells uniquely yours. The flavor combinations are truly endless, guaranteeing a new and exciting experience every time!

How to Make Perfect Smoked Shotgun Shells: A Step-by-Step Guide

Creating these delicious smoked shotgun shells is a straightforward process, but paying attention to a few key details will ensure a perfect outcome every time. Follow these steps for an amazing appetizer:

Step 1: Prepare Your Ingredients and Workspace

Begin by taking your cream cheese out of the refrigerator and allowing it to soften to room temperature. This is crucial for a smooth and even mixture. Shred your mozzarella cheese and set it aside. While you can buy pre-shredded cheese, freshly shredded cheese melts much better and tastes superior.

Next, prepare your workstation. Set up a wire rack over a large sheet pan. Lining the sheet pan with aluminum foil is highly recommended – trust me, your cleanup (and your spouse) will thank you for saving them from sticky, bacon-grease-coated pans!

Step 2: Create the Flavorful Filling

In a large mixing bowl, combine the ground Italian sausage, the softened cream cheese, the shredded mozzarella cheese, and two teaspoons of your favorite barbecue rub. Use your hands (or a sturdy spoon) to thoroughly mix all the ingredients until they are well combined. You want a homogeneous mixture where the cheese and rub are evenly distributed throughout the sausage. This ensures every bite is packed with flavor.

Step 3: Stuff the Manicotti Shells

Now for the stuffing! Transfer the meat mixture into a disposable piping bag. If you don’t have a piping bag, a large Ziploc bag with a corner snipped off will work. Cut the tip of the piping bag to create an opening large enough for the mixture to pass through easily. Take an **uncooked manicotti shell** and squeeze the pork mixture into it, filling it about halfway. Then, turn the pasta tube around and fill the other half from the opposite end. This two-sided approach helps to ensure the shell is completely and evenly stuffed.

If you don’t have a piping bag, don’t worry! Any kitchen utensil that can fit inside the shell can be used. We’ve found that a mini spatula, like our beloved Tolovo mini spatula, or even a small spoon, works perfectly. We’ve tried both piping and spoon-stuffing, and neither method was definitively superior in terms of the final product. The key is to ensure each manicotti pasta is completely and firmly stuffed. Filling halfway from one end, then turning and filling from the other end, makes this a surprisingly quick and easy task.

Step 4: Wrap with Bacon

Once your shells are stuffed, it’s time for the bacon wrap! Carefully take a slice of bacon and wrap it around each stuffed shell. The goal is to completely cover the entire surface of the shell with bacon. Make sure the ends of the bacon slices extend to the very ends of the manicotti tubes. This is crucial for two reasons: firstly, it ensures maximum bacon flavor and crispiness; and secondly, the rendered bacon fat, combined with the moisture from the meat mixture, will help to soften the uncooked pasta during the resting period, preventing any unpleasantly crunchy spots in your finished bacon-wrapped shotgun shells. Nobody wants crunchy pasta!

Step 5: Season and Rest

Place your bacon-wrapped stuffed shells onto the prepared wire rack in the large sheet pan. Now, liberally apply your favorite barbecue rub over the entire surface of each shotgun shell. Don’t be shy – make sure they are completely coated! This rub will form a delicious crust and infuse the shells with incredible flavor during smoking.

Here’s a critical step that truly sets these smoked shotgun shells apart: they need to rest for a minimum of four to six hours before smoking. Our recommendation would be to rest them overnight for the best results. During this resting period, a magical transformation occurs: the moisture from the meat and cheese mixture, combined with the fats from the bacon, begins to absorb into the raw pasta. This process is essential for softening the manicotti, ensuring it cooks up tender and flavorful on the smoker, preventing any hard or chewy sections. If resting overnight, simply cover the sheet pan with plastic wrap and refrigerate. Remember to pull them out about an hour before you plan to smoke them, allowing them to come closer to room temperature.

Step 6: The Smoking Process

When you’re ready to cook, preheat your smoker to 250 degrees Fahrenheit (approximately 120 degrees Celsius). As for wood choice, there’s no truly “wrong” answer here; use what you prefer! I personally lean towards an aggressive hickory wood for its bold, smoky flavor that stands up well to the richness of the shells. However, apple wood or cherry wood would also be excellent choices, offering a slightly sweeter and milder smoke profile.

Carefully place the shotgun shells on your smoker grates, ensuring they are positioned away from direct heat (if your smoker has hot spots). You can leave them on the sheet pan with the wire rack (which we find makes them easier to handle) or place them directly on the grill grates. Allow them to smoke for one hour at 250°F.

After the first 30 minutes of smoking, it’s a good idea to rotate the shells (or turn the entire baking sheet if using one) to ensure even cooking and smoke penetration on all sides.

Step 7: Crisp and Sauce

After the initial hour of smoking, increase the smoker’s temperature to 350 degrees Fahrenheit (approximately 175 degrees Celsius) and continue cooking for about 15 minutes. This higher temperature is key to crisping up that bacon beautifully. Keep an eye on them, as bacon crispiness is a matter of personal preference.

Once the bacon has reached your desired level of crispiness, it’s time for the final touch: apply a generous coat of your favorite barbecue sauce over each smoked shotgun shell. Return them to the smoker and continue cooking at 350°F for another 15 minutes. This allows the sauce to caramelize and meld with the smoky flavors.

Step 8: Rest and Serve

Once your smoked shotgun shells are beautifully glazed and the bacon is perfectly crispy, remove them from the smoker. Allow them to rest for about 5 minutes. This short resting period helps the sauce to “set up” and prevents it from running off when you serve them.

After a brief rest, they are ready to serve! We particularly enjoy cutting them into bite-sized medallions (about 1-inch thick slices). This makes them perfect for sharing and allows everyone to enjoy several delicious bites of this yummy, smoked appetizer without too much commitment. The combination of crispy bacon, tender sausage and cheese filling, and the spicy-sweet barbecue sauce creates a truly fabulous bite. The layers of flavor come together beautifully in every morsel.

This bacon-wrapped shotgun shells recipe is especially convenient for those using a pellet grill or other electric smokers, where precise temperature control is as simple as turning a knob. However, if you’re working with an offset smoker or a classic Weber kettle, there’s no problem at all. Just ensure you smoke the shotgun shells over indirect heat. To achieve that final bacon crispiness and sauce caramelization, you can easily finish them off by firing up your oven or even an air fryer for a few minutes once they’re off the smoker.

Serving and Leftovers

We recently served these up for a few guests, and they were an absolute hit – so much so that the leftovers mysteriously left with them! We’ve made these with the listed Italian sausage and mozzarella, and also tried them with breakfast sausage and cheddar. While both are delicious, we generally find the Italian sausage and mozzarella combination offers a richer, more complex flavor profile than the breakfast sausage alternative.

Should you be lucky enough to have any leftovers, store them in an airtight container in the refrigerator. To reheat, place them in the oven at 325 degrees Fahrenheit (approximately 160 degrees Celsius) for about 20 minutes. This will help to re-crisp the bacon. A crucial tip for reheating: add a touch more barbecue sauce to them before warming. I’ve noticed they can be a little dry without that extra bit of moisture from fresh sauce.

So, if you’re searching for something new, fun, and incredibly delicious to serve at your next barbecue or gathering, smoked shotgun shells are definitely worth exploring. They are perfect for big cookouts; you can easily prepare a couple of large batches in advance and either serve them directly at your party or take them along to a potluck with friends or family. Either way, these unique bacon-wrapped manicotti will undoubtedly be a big hit!

Frequently Asked Questions About Smoked Shotgun Shells

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