Name: Smoked Shotgun Shells – Pellet Grill Recipes for Meat Lovers
Prep time: 20 min
Cook time: 135 min
Total time: 155 min
Ingredients: 1 box manicotti shells, uncooked; 1 pound ground Italian sausage (or spicy sausage if you like heat); 1 cup shredded cheddar cheese; 1 tablespoon BBQ dry rub; 12 slices thick-cut bacon; 1 cup BBQ sauce (your favorite brand)

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Some recipes scream ‘weekend warrior’, and these smoked shotgun shells? They’re it. You wrap seasoned ground beef and gooey cheese in manicotti pasta, then roll that in bacon, and smoke it until everything melds into one glorious, bite-sized meat bomb. I mean, who looks at manicotti and thinks, ‘Yeah, let’s turn that into a bacon-wrapped smoked sausage grenade?’ Me. Apparently me. This is the kind of thing I make when I want to impress my neighbors and terrify vegetarians at the same time. You don’t need a degree in grill mastery, just a pellet smoker and a bit of patience. Whether you’re a Pit Boss fan or just someone who loves smoked meat recipes, this one delivers all the smoky, cheesy, slightly-crispy satisfaction. Don’t be surprised if this becomes your new best stuffed shells recipe to bring to cookouts, tailgates, or honestly, a Monday night. The key is time. Let those shells sit overnight so the pasta softens, and you won’t break a tooth trying to eat them. Then give ’em a couple of hours on your pellet grill, and boom—magic.

1) Key Takeaways
2) Easy Smoked Shotgun Shells Recipe
3) Ingredients for Smoked Shotgun Shells
4) How to Make Smoked Shotgun Shells
5) Tips for Making Smoked Shotgun Shells
6) Making Smoked Shotgun Shells Ahead of Time
7) Storing Leftover Smoked Shotgun Shells
8) Try these Appetizers next!
9) Smoked Shotgun Shells
10) Nutrition

1) Key Takeaways

What meat works best in stuffed shells for smoking?
How long do you cook shotgun shells on a pellet grill?
Can you make shotgun shells in advance?
What’s the secret to keeping stuffed pasta moist on the grill?

2) Easy Smoked Shotgun Shells Recipe

I’ve smoked all kinds of things, but these shotgun shells might be the wildest idea that actually works. We’re talking pasta stuffed with sausage and cheese, hugged by a slice of bacon, then slow-cooked on a pellet grill until everything sings. Twice. Pellet grill recipes often fall into the “set it and forget it” category, and this one fits right in.

When I made this at a backyard birthday party, the tray vanished before the burgers even hit the grill. It’s the kind of recipe that gets people talking with their mouths full. I love how the manicotti softens just enough while holding all that meaty, smoky goodness inside. The best part? It looks impressive but doesn’t need fancy equipment or pro-level skills.

This stuffed shells recipe is for those who want flavor that punches you in the taste buds without punching your wallet. No need to boil the shells, just let them sit overnight in the fridge to soak up moisture from the filling. That step makes all the difference. So fire up your smoker and get ready to ruin regular appetizers for everyone else.

3) Ingredients for Smoked Shotgun Shells

Manicotti Shells: These pasta tubes are thick, strong, and perfect for stuffing. You don’t need to pre-cook them. They’ll soften overnight in the fridge while wrapped in bacon. That saves time and dishes.

Ground Italian Sausage: I go with a spicy version, but sweet or mild sausage works too. It gives that juicy, savory base to your smoked meat recipes and stays moist during the slow cook.

Shredded Cheddar Cheese: Cheddar melts well and brings a sharp, creamy contrast to the sausage. You can mix in mozzarella if you’re feeling fancy or swap for pepper jack to kick up the heat.

BBQ Dry Rub: I use a smoky blend that includes paprika, garlic powder, onion powder, and a little brown sugar. It adds depth to the meat and gives the bacon a flavorful crust as it cooks.

Thick-Cut Bacon: Thin bacon shrinks and tears. Go thick. It crisps up just right and locks everything together. That smoky, salty layer on the outside might be the best part of this whole recipe for stuffed shells.

BBQ Sauce: Brush it on near the end. I like mine sweet and sticky, but tangy sauce works just as well. It caramelizes over the bacon and ties the whole thing together with that pit boss pellet grill flavor.

4) How to Make Smoked Shotgun Shells

Step 1: Mix sausage, cheese, and BBQ rub in a large bowl. I use my hands, but gloves make cleanup easier. You want everything well combined so every bite tastes the same.

Step 2: Gently stuff each manicotti shell with the sausage mixture. I like to pipe it in using a zip-top bag with the corner cut off. Don’t overfill or the bacon won’t wrap properly.

Step 3: Wrap each stuffed shell in a slice of thick-cut bacon. Start at one end and spiral to the other. If the bacon’s short, stretch it a little—just don’t tear it.

Step 4: Place the shells in a shallow container, cover, and chill overnight. This softens the pasta and lets the flavors settle. Trust me, this step matters more than it sounds.

Step 5: Preheat your pellet smoker to 250°F. Lay the shells directly on the grates. Cook for 2 hours, turning once halfway if you’re the fussy type.

Step 6: In the last 15 minutes, brush on BBQ sauce. The glaze bubbles and sets into a sticky layer. Pull them off the grill when the bacon is cooked to your liking.

5) Tips for Making Smoked Shotgun Shells

Wrap tightly. Loose bacon flaps don’t cook well. Start the wrap snug, and if needed, use toothpicks to keep everything in place until the fat renders and holds it all together.

Chill overnight. This helps soften the pasta and gives the sausage a head start on flavor. It’s like a marinade in pasta form. Skip this, and you’ll end up with chewy shells and uneven cooking.

Check internal temp. You’re aiming for around 165°F inside. That confirms the meat’s cooked, and you can relax knowing everything’s safe and delicious. This is one of those smoker recipes pellet grills do well without babysitting.

6) Making Smoked Shotgun Shells Ahead of Time

You can prep everything the night before—actually, you should. Stuff the shells, wrap in bacon, and let them rest overnight. The texture improves, and they cook more evenly on the grill.

If you’re planning a backyard cookout or tailgate, this gives you a big head start. In the morning, you just light the pellet grill, grab your shells, and smoke. No scrambling with raw meat or hunting for bacon at 9 AM.

They also travel well. I’ve brought them packed in foil pans to family reunions and cookouts. You can smoke them on-site or pre-cook and reheat wrapped in foil at 300°F for 20 minutes. Pellet grill recipes that hold up like this are a win for planners.

7) Storing Leftover Smoked Shotgun Shells

If you manage to have leftovers, they store well. Wrap each one in foil and keep them in the fridge for up to four days. The bacon holds up surprisingly well and stays crispy with a quick reheat.

For longer storage, freeze them. Wrap tightly, then stash them in a freezer bag. Reheat in the oven at 325°F until warmed through. Just know that like most smoked meat recipes, they’re best fresh off the grill.

I’ve even tossed leftovers into a breakfast scramble. Chop the shells, toss with eggs and cheese, and it turns into a meaty, smoky morning feast. Not bad for something that started as a party snack.

8) Try these Appetizers next!

9) Smoked Shotgun Shells