Smoked shotgun shells are manicotti tubes filled with Italian sausage, cream cheese, and shredded mozzarella, wrapped in bacon, seasoned with a barbecue rub, then smoked and finished with barbecue sauce. They make a flavorful, finger-friendly appetizer that’s great for cookouts and gatherings.
When my sister-in-law first mentioned smoked shotgun shells, I was skeptical, then curious. If you enjoy smoking and serving shareable appetizers, these checks a lot of boxes: sausage, cheese, pasta, bacon, rub, and smoke. The result is rich, smoky bites that travel well from smoker to plate.
Why This Recipe Works
This recipe yields a plentiful batch of appetizer bites packed with complementary flavors and textures. The sausage and cheeses provide a savory, creamy interior while the bacon crisps and the barbecue sauce adds sweetness and tang. The uncooked manicotti holds the filling and softens during the resting process so it won’t turn crunchy during smoking.
There are no exotic ingredients required—most are pantry or grocery staples—so they’re easy to prepare. You can also experiment with different fillings, cheeses, and rubs to customize the flavor profile. The hands-on prep is straightforward and the actual time on the smoker is relatively short, so you can prepare them in advance and finish them the day of your event.
Tips And Variations
Our version uses Italian sausage, cream cheese, and mozzarella. Here are some variations to try:
- Use hot or mild breakfast sausage and swap mozzarella for cheddar for a sharper taste.
- Blend ground pork and beef 50/50 for a different meaty texture.
- Add chopped jalapeño, green onion, or cilantro to the filling for brightness and heat.
- Try Monterey Jack, Pepper Jack, or smoked gouda for different cheese notes.
- Experiment with different rubs and barbecue sauces to change the final flavor.
This is a flexible recipe that invites creativity—mix and match to find a version your guests will love.
How To Make Smoked Shotgun Shells
Set the cream cheese out to reach room temperature and shred the mozzarella. Line a large sheet pan with foil and place a wire rack on top for smoking.
Combine 1 lb Italian sausage, 4 oz cream cheese, 4 oz shredded mozzarella, and 2 teaspoons barbecue rub in a large bowl. Transfer the mixture into a disposable piping bag (or use a small spatula or spoon) and fill uncooked manicotti shells halfway, then rotate and finish filling the other half so each tube is completely full.
You can use cannelloni if you prefer; they’re slightly smaller and smoother, but work the same way.
Wrap each stuffed shell in bacon, ensuring the bacon covers the entire tube and reaches the ends. The bacon fat will help soften the pasta and prevent crunchy, undercooked spots. Standard-cut bacon works well; thick-cut can be used if you want a meatier bite.
Place the bacon-wrapped shells on the wire rack and coat them generously with barbecue rub. Let them rest for at least four to six hours so the filling releases moisture into the raw pasta; overnight resting is ideal. If refrigerating, cover the tray with plastic wrap and bring them to near room temperature about an hour before smoking.
Preheat your smoker to 250°F and choose a smoking wood you like—hickory gives an assertive flavor; apple is milder and sweeter. Place the shells away from direct heat and smoke for one hour, rotating the pan after 30 minutes for even exposure.
After an hour, raise the smoker to 350°F and cook about 15 minutes to crisp the bacon. Brush on about 1/2 cup of your favorite barbecue sauce and continue at 350°F for another 15 minutes so the sauce sets and becomes glossy. Remove the shells and let them rest for 5 minutes before serving.
These work well on pellet grills and electric smokers where temperature is easy to control, but you can also smoke them using indirect heat on a Weber or offset smoker. If needed, finish in a hot oven or air fryer to crisp the bacon.
We like to slice them into bite-sized medallions for serving. The contrast of bacon, seasoned sausage, melty cheese, and tangy-sweet sauce is a crowd-pleaser.
Leftovers can be stored in an airtight container and reheated at 325°F for about 20 minutes to re-crisp the bacon. Add a touch more barbecue sauce when reheating if they seem dry.
These smoked shotgun shells are great to make in large batches for parties. They travel well and are an easy appetizer to serve warm or at room temperature. We tested versions with breakfast sausage and cheddar, but we preferred the depth of flavor from Italian sausage and mozzarella.
If you’re looking for a new appetizer to impress guests, these are worth trying. They’re simple to prepare, customizable, and reliably popular with crowds.
FAQ
A smoked shotgun shell is a manicotti or cannelloni tube stuffed with a seasoned meat and cheese mixture, wrapped in bacon, smoked, and finished with barbecue sauce.
Smoke them at 250°F for one hour, then increase to 350°F and cook about 15 minutes to crisp the bacon, finish with sauce and another 15 minutes if desired.
Yes. Store in an airtight container and reheat at 325°F for about 20 minutes to re-crisp the bacon. Add extra barbecue sauce if needed.
Other Amazing Barbecue Recipes
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- Fall-Apart Smoked Chuck Roast Recipe
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Smoked Shotgun Shells Recipe
Ingredients
Mixture
- 1 lb Italian sausage
- 4 oz Mozzarella cheese
- 4 oz Cream cheese
- 2 tsp Barbecue rub
Shotgun Shells
- 12 Manicotti shells
- 1 lb Bacon
- 1/2 cup Barbecue sauce
- 1/2 cup Barbecue rub
Instructions
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Set the cream cheese out until it’s room temperature. Shred the mozzarella and set aside.
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Combine Italian sausage, cream cheese, shredded mozzarella, and 2 tsp barbecue rub in a large bowl.
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Add the mixture to a piping bag or use a small spatula. Fill each uncooked manicotti shell completely.
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Wrap each filled shell with bacon, covering the entire tube and reaching the ends.
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Place the wrapped shells on a wire rack over a sheet pan, coat with a generous amount of rub, and allow to rest 4 hours to overnight.
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Preheat smoker to 250°F. Smoke the shells away from direct heat for 1 hour, rotating after 30 minutes.
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Increase smoker temperature to 350°F and cook about 15 minutes to crisp the bacon. Brush with barbecue sauce and continue at 350°F for another 15 minutes.
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Remove from smoker, let rest 5 minutes, then serve whole or sliced into medallions.
Nutrition
| Carbohydrates: 18 g
| Protein: 15 g
| Fat: 33 g