BBQ Shotgun Shells – Bacon-Wrapped, Cheesy, and Meaty Party Appetizer

Looking to surprise your guests with the ultimate crowd-pleasing appetizer? Enter BBQ Shotgun Shells—a wildly popular BBQ snack that’s making waves at backyard cookouts, game day gatherings, and any event where finger food is king. These savory bites are made with manicotti pasta stuffed with seasoned ground meat and cheese, wrapped in smoky bacon, brushed with your favorite BBQ sauce, and smoked or baked to melty, crispy perfection. They’re called “shotgun shells” for their tubular shape and the explosive flavor packed in each bite.

Overview of BBQ Shotgun Shells

BBQ Shotgun Shells are the perfect fusion of comfort food and BBQ magic. Each piece starts with a pasta shell filled with a creamy, meaty, cheesy mixture—think of it as a cross between a stuffed pasta and a jalapeño popper, but heartier. The filling is typically a blend of ground beef or sausage, cream cheese, and shredded cheddar, seasoned generously for a bold flavor profile. Wrapping each stuffed shell in bacon ensures that every bite is crisp and smoky, while a brush of BBQ sauce at the end caramelizes into a sticky, flavorful glaze.

They can be prepared ahead, smoked or oven-baked, and are ideal for parties since they’re delicious served hot or at room temperature. Their playful appearance and “shotgun shell” name make them a guaranteed conversation starter at your next event.

Ingredients of all BBQ Shotgun Shells

Here’s what you’ll need to create classic BBQ Shotgun Shells. Ingredients can be adjusted for heat and flavor according to your preference.

For the Filling:

• 1 pound ground beef (or pork sausage, or a mix)
• 1 cup shredded cheddar cheese
• 4 oz (half a block) cream cheese, softened
• 1/4 cup finely chopped green onions
• 1 tablespoon BBQ dry rub seasoning (plus more for sprinkling)
• 1/2 teaspoon garlic powder
• 1/2 teaspoon onion powder
• 1/4 teaspoon smoked paprika
• Salt and black pepper to taste

Assembly:

• 10–12 manicotti pasta shells (uncooked)
• 10–12 slices thin-cut bacon
• 1/2 cup BBQ sauce (your favorite, for glazing)

Optional Add-Ins:

• Diced jalapeños or hot sauce (for heat)
• Crumbled cooked bacon inside the filling
• Shredded Monterey Jack or pepper jack cheese

Garnish:

• Chopped parsley or chives

How to Make BBQ Shotgun Shells

While the name may sound a little wild, the process is straightforward. The key is prepping the filling and allowing the stuffed shells to “marinate” so the pasta softens before they hit the smoker or oven. This ensures the shells cook through and absorb flavor. Here’s how you do it, step by step.

Step-by-Step Instructions

1. Make the Filling

In a large bowl, combine ground beef (or sausage), shredded cheddar, cream cheese, chopped green onions, BBQ dry rub, garlic powder, onion powder, smoked paprika, and a pinch of salt and pepper. Mix thoroughly until all ingredients are well incorporated. If you want a spicier bite, fold in diced jalapeños or a splash of hot sauce.

2. Stuff the Manicotti Shells

Carefully fill each uncooked manicotti shell with the meat and cheese mixture. The easiest method is to use your hands or a piping bag for even, compact filling. Be gentle so you don’t break the shells—uncooked pasta is sturdy, but stuffing too forcefully can cause cracks.

3. Wrap with Bacon

Lay out a strip of thin bacon. Place a stuffed manicotti shell at one end and roll it up so the bacon completely covers the pasta. If your bacon strips are short, use two overlapping strips to cover the shell. Repeat with all the stuffed shells.

4. Marinate and Rest

Arrange the bacon-wrapped shells on a baking sheet or platter. For best results, cover and refrigerate for 4 hours or overnight. This resting step allows the dry pasta to absorb some moisture from the filling and bacon, ensuring the shells soften and cook fully during baking or smoking.

5. Cook the Shotgun Shells

Smoker Method (Preferred for Authentic BBQ Flavor):

• Preheat your smoker to 250°F (120°C) with your favorite wood (hickory or applewood are great choices).
• Arrange the shells on the rack, seam side down.
• Smoke for 1 hour, then brush with BBQ sauce.
• Continue smoking for another 30–45 minutes, or until the bacon is crispy and the filling is cooked through.

Oven Method:

• Preheat your oven to 300°F (150°C).
• Place the shells on a wire rack set over a baking sheet (to catch drips).
• Bake for 1 hour. Brush with BBQ sauce.
• Bake for an additional 20–30 minutes, or until the bacon is crisp and the internal temperature reaches 165°F (74°C).

6. Glaze and Finish

During the last 20–30 minutes of cooking, generously brush each shell with BBQ sauce. This step ensures a shiny, flavorful glaze and encourages caramelization for sticky, finger-licking goodness.

7. Serve and Garnish

Remove the BBQ Shotgun Shells from the smoker or oven and let rest for 5–10 minutes before slicing. Garnish with fresh parsley or chives and serve hot. They’re delicious on their own or with extra BBQ sauce for dipping.

Cook and Prep Times

Step	Time
Prep Time	30 minutes
Resting Time	4 hours (minimum)
Cook Time	1.5 hours
Total Time	~6 hours (with rest)
Servings	10–12 shells

Note: The hands-on time is around 30 minutes; most of the time is resting/cooking.

Nutrition Information (Per Shell, Approximate)

• Calories: 285
• Protein: 16g
• Carbohydrates: 13g
• Fat: 18g
• Saturated Fat: 7g
• Cholesterol: 55mg
• Sodium: 420mg
• Sugar: 4g

Nutritional values may vary depending on the type of meat, bacon, and BBQ sauce used.

Tips and Variations

• Don’t skip the rest: Resting allows the pasta to soften for the best bite.
• Use thin bacon: Thick bacon won’t crisp up as easily.
• Check doneness: Use a thermometer to ensure the filling reaches 165°F (74°C).
• Add heat: Jalapeños or hot sauce can be mixed in for a spicier shell.
• Make ahead: These can be assembled up to a day in advance, perfect for party prep.

What to Serve With BBQ Shotgun Shells

• Classic coleslaw or potato salad
• Baked beans
• Pickles or pickled jalapeños
• Grilled corn on the cob
• Extra BBQ sauce for dipping

Common Mistakes to Avoid

• Skipping the rest: The pasta won’t soften enough and will be chewy.
• Using thick-cut bacon: It takes longer to crisp and can remain rubbery.
• Overstuffing: The filling may burst out if packed too tightly.
• Not using a rack: A rack ensures even cooking and crispy bacon all around.

Brief Recipe Card

BBQ Shotgun Shells

Servings: 10–12 | Prep: 30 min | Rest: 4 hr | Cook: 1.5 hr

Ingredients:

• 1 lb ground beef or sausage
• 1 cup shredded cheddar
• 4 oz cream cheese
• 1/4 cup green onions
• 1 tbsp BBQ dry rub
• 10–12 manicotti shells (uncooked)
• 10–12 strips thin bacon
• 1/2 cup BBQ sauce
• Garlic powder, onion powder, smoked paprika, salt, pepper

Instructions:

1. Mix all filling ingredients.
2. Stuff uncooked manicotti shells with filling.
3. Wrap each with bacon.
4. Rest in fridge 4 hours or overnight.
5. Smoke at 250°F for 1 hour, brush with BBQ sauce, then 30–45 min more until bacon is crisp.
   (Or bake at 300°F for 1 hour, then 20–30 min after saucing.)
6. Rest briefly, slice, and serve hot.