
Smoked Shotgun Shells
Learn to make Southwestern smoked shotgun shells — manicotti stuffed with seasoned meat, cheese, and hatch chilies, wrapped in smoky bacon.
Smoked Shotgun Shells
Rated 3.5 stars by 2 users
Category
Appetizer
Cuisine
Southwestern
Author:
This recipe comes from Matt Pittman, CEO of Meat Church BBQ, YouTube personality, and friend of Montana Knife Company.
Servings
24
Prep Time
30 minutes
Cook Time
75 minutes
Calories
518
These smoked shotgun shells are a knockout appetizer that combines manicotti pasta, seasoned meat, and smoky bacon.
After years of testing different smoked shotgun shells recipes, I’ve landed on this Southwestern-inspired version packed with meat, cheese, and hatch chilies. Serve it at your next tailgate and get ready to hear your guests clamor for more.

Ingredients
The following ingredients make the perfect smoked shotgun shells:
- 2 boxes manicotti shells
- 2 packages regular bacon
- 1 lb. 90/10 ground beef
- 1 lb. sweet Italian sausage links (5–6 sausages)
- 8 oz. farm-cut shredded cheese
- Meat Church Honey Hog seasoning
- 1 cup sweet BBQ sauce (I use Meat Mitch Naked)
- 4 roasted hatch chilies, diced with a clean, sharp kitchen knife (jalapeños work too)
Directions
Whip up this Southwestern smoked shotgun shells recipe in four easy steps:
1. Mix your filling
Remove sausage from casings.
Combine sausage, ground beef, and shredded cheese in a large bowl.
Mix in diced chilies if using. (Don’t forget to clean and sharpen your knife before dicing. Not only does it keep your kitchen and tailgate guests safe, but it elevates the smoked shotgun shells’ presentation tenfold.)
2. Assemble the smoked shotgun shells
Stuff manicotti tubes completely with meat mixture.
Wrap each shell in bacon, covering as much surface as possible.
Season all sides with Honey Hog.
Place on a sheet pan and refrigerate for four-plus hours or overnight.
3. Smoke your shotgun shells
Preheat your smoker to 300°F. Use medium smoke wood like hickory or pecan.
Place shells on a baking rack in the smoker.
Smoke for one hour (meat should reach 165°F internal temp).
Brush with BBQ sauce.
Return to the smoker for 10–15 minutes until sauce sets.
Serve and enjoy!
This recipe yields about 24 shells. I’ve found that hickory or pecan wood gives these smoked shotgun shells the perfect smoke flavor without overpowering the meat and cheese filling.
Recipe Note
Tips for Smoked Shotgun Shells Recipe Success
Want to be the culinary victor of your next tailgate? Follow these smoked shotgun shells tips:
- When you store your smoked shotgun shells in the fridge, keep them level on a rimmed baking sheet to catch any leaks. For overnight resting, cover them loosely with plastic wrap. I’ve tested shorter rest periods, and they just don’t deliver the same tender results.
- Take the smoked shotgun shell meat out 30 minutes before mixing so it comes to room temperature. Mix by hand to get the perfect texture, but don’t overwork it. Before filling all your shells, cook a small patty to test the seasoning. Use a piping bag or zip-top bag with the corner cut off for the cleanest filling process.
- Stretch the bacon slightly as you wrap for better coverage, and overlap it so it doesn’t unwrap during cooking.Always place the seam side down on the rack. Regular-cut bacon works better than thick-cut here — it wraps easier and cooks more evenly.
- Keep that smoker lid closed as much as possible to maintain temperature.Space the shells at least an inch apart, and if your smoker runs hot in certain spots, rotate the rack halfway through. Hold off on the sauce until you see the bacon starting to brown, and use a brush instead of a mop to apply it.
- When it’s time to serve, give your smoked shotgun shells about five minutes to rest before slicing.Use a sharp, clean knife to cut them on a slight diagonal for the best presentation.
I’ve learned all these tricks through trial and error. What started as a fun experiment has become one of my most requested cookout dishes.
The attention to detail pays off in the final product: each smoked shotgun shell comes out perfectly tender with a beautiful balance of smoke, meat, and cheese.