Pasta shells filled with sausage, cheese and hot peppers, smoked and finished with a glaze of BBQ sauce. These smoked shotgun shells make an outstanding appetizer for parties and holiday gatherings — flavorful, satisfying, and guaranteed to disappear fast.
What are Smoked Shotgun Shells?
Shotgun shells are a popular appetizer named for their resemblance to actual shotgun shells. They’re made from large pasta shells stuffed with a savory meat-and-cheese filling. This version adds a little heat from jalapeño and serrano peppers and a sweet BBQ glaze after smoking for a delicious contrast of smoky, spicy and sweet flavors.
Ingredients
All ingredients are available at most grocery stores. Manicotti or large pasta shells can sometimes be out of stock, so you may need to check a couple of stores.
- Manicotti shells (large pasta shells)
- Jimmy Dean breakfast sausage (regular or hot)
- Bacon (thin cut)
- Cheddar cheese (shredded)
- Red bell pepper (chopped)
- Jalapeño (chopped)
- Serrano pepper (chopped)
- BBQ sauce (sweet)
Video – How to make shotgun shells (step-by-step)
How to Make Shotgun Shells
Follow these steps for tender pasta shells filled with a cheesy, spicy sausage mixture and wrapped in crispy smoked bacon. The pasta is par-boiled first and finishes cooking on the smoker.
Par-Boiling the Shells
Do not skip par-boiling. It ensures the shells finish perfectly on the smoker. Bring a large pot of water to a boil and have a bowl of ice water ready. Add the shells and boil for 4 minutes. Remove with tongs or a slotted spoon and immediately plunge them into the ice water to stop cooking. The pasta should still be slightly underdone—it will finish on the smoker.
Making the Stuffing Mixture
In a large bowl, combine the sausage, shredded cheddar, chopped red bell pepper, jalapeño and serrano. Mix thoroughly by hand until evenly combined.
If you prefer less heat, use mild breakfast sausage and omit the hot peppers. Italian sausage can be used as an alternative if desired.
Stuffing the Shells
Pat the shells dry with paper towels after they cool. Wearing gloves, use your hand to gently stuff each shell. Start at one end and fill about half the shell, then begin at the opposite end and finish filling the rest. Be careful not to split the pasta.
Wrapping in Bacon
Wrap each stuffed shell with thin-cut bacon. Thin bacon crisps and cooks through more reliably than thick cut. Wrap starting at one end and secure with toothpicks. It usually takes one to two strips per shell; two strips provide good coverage and will shrink while cooking.
Cooking the Bacon-Wrapped Shotgun Shells
Now it’s time to smoke them. The low, steady heat will cook the filling, crisp the bacon and add great smoky flavor.
Fire up the Smoker
Preheat your smoker to 270°F using mild fruit or nut woods for smoke. Applewood or hickory work well. Place the bacon-wrapped shells directly on the grill grates.
Smoke until the internal temperature of the sausage reaches 155°F, about 1.5 hours. There’s no need to flip the shells while smoking.
Baste with BBQ Sauce
When the filling hits 155°F, brush a sweet BBQ sauce on both sides of each shell. Continue smoking for 5–10 minutes to set the glaze and bring the internal temperature to 160°F. Remove with tongs and transfer to a serving platter.
Serving & Flavor
Remove toothpicks before serving. For parties, cut each shell in half so they’re easy finger-food portions. The combination of sausage, cheese and peppers creates a rich, balanced filling that pairs beautifully with the smoky bacon and sweet BBQ glaze.
Leftovers & Reheating
Store leftovers in an airtight container in the refrigerator for 3–4 days. To reheat, place on a baking sheet in a 375°F oven for about 10 minutes or until heated through.
Pro Tips
- Cook to internal temperature rather than relying solely on time to avoid overcooking the pasta ends.
- Use a sweet BBQ sauce to balance the heat from the peppers.
- Choose thin-cut bacon so it cooks evenly and crisps nicely.
- Par-boil the pasta for 4 minutes before stuffing so the shells finish tender on the smoker.
Pair With These Other Appetizers
- Smoked Jalapeño Poppers
- Pigs in a Blanket
- Caprese Skewers
- Smoked Deviled Eggs
- Shrimp Cocktail
Smoked Shotgun Shells
Ingredients
- 12-16 each manicotti shells
- 2 lbs Jimmy Dean sausage (hot)
- 8 oz cheddar cheese (shredded)
- 2 lbs bacon (thin cut)
- 1 each red bell pepper (chopped)
- 1 each jalapeño (chopped)
- 1 each serrano pepper (chopped)
- ½ cup barbecue sauce (sweet)
Instructions
-
Bring a large pot of water to a boil and add the manicotti shells. Boil for 4 minutes, then remove and place shells into a bowl of ice water to stop cooking.
-
While the pasta cools, mix the sausage, cheddar, red bell pepper, jalapeño and serrano together in a bowl until evenly combined.
-
Pat the shells dry. Stuff each shell by filling half from one end, then filling the remaining half from the other end. Take care not to split the pasta.
-
Wrap each stuffed shell with thin-cut bacon, using toothpicks to secure as needed. Two strips per shell works well.
-
Preheat smoker to 270°F and place shells directly on the grill grate. Smoke until the sausage reaches 155°F internal temperature, about 1.5 hours.
-
Brush a sweet BBQ sauce on both sides once the shells reach 155°F and continue smoking 5–10 minutes until the internal temperature reaches 160°F and the sauce sets.
-
Remove from smoker, discard toothpicks, and cut shells in half for party-sized servings. Serve warm.
Pro Tips
- Always cook to internal temperature to avoid overcooking the pasta ends.
- Sweet BBQ sauce balances the heat from the peppers.
- Thin-cut bacon crisps and cooks through more reliably than thick-cut bacon.
- Par-boil the pasta for 4 minutes before stuffing to ensure the shells finish tender on the smoker.