There’s something about pulling a tray of bacon-wrapped shotgun shells off the smoker that immediately grabs attention. The bacon is tight and caramelized, the glaze is glossy, and when you slice into one, you see layers of seasoned beef, sausage, jalapeños, and melted cheese packed inside tender pasta.

Smoked Shotgun Shells | Heath Riles BBQ

These Smoked Shotgun Shells are bold without being complicated. They’re built on simple ingredients layered intentionally — lean ground beef for structure, Italian sausage for richness, jalapeños and garlic for balance, thick-cut cheddar for creamy melt, and thin bacon wrapped edge to edge so it renders properly at 300°F.

Cooked low and steady on the Recteq Flagship 1600 using Royal Oak Charcoal & Hickory Blended Pellets, this recipe delivers real smoke flavor without overpowering the filling.

If you’re looking for a smoked appetizer that eats like a meal and slices clean for serving, this one belongs in your rotation.

Why These Shotgun Shells Work

Shotgun shells have gone viral for a reason — but not all of them turn out the way they should. The difference between good and great comes down to a few key details:

• Lean beef matters. Using ground sirloin instead of high-fat ground beef keeps the filling moist without pushing out excessive grease during the cook. Too much fat can prevent the shells from setting properly and can make the final bite feel heavy.
• The refrigerator rest is critical. These shells go on the smoker with uncooked manicotti. Letting them sit wrapped in bacon for several hours allows moisture from the meat and bacon to begin softening the pasta before it ever hits heat. Skip this step and the texture won’t be the same.
• Controlled heat at 300°F makes the difference. Running your cook steady on the Recteq Flagship 1600 allows the bacon to render properly, the cheese to melt evenly, and the filling to cook through without scorching the outside.
• Glazing at the end protects the finish. Adding the sauce during the final few minutes keeps it from burning and gives you that tacky, polished look that makes these shells as impressive visually as they are flavorful.

This recipe isn’t complicated — it’s just built intentionally.

The Ingredients

• Manicotti Shells. The backbone of the recipe. These go on uncooked, which is why resting before cooking is essential.
• Lean Ground Beef (1 lb). Ground sirloin works best. Lean beef prevents excess grease and gives the filling structure.
• Italian Sausage (1 lb). Use mild or hot depending on your preference. This brings richness and depth that balances the lean beef.
• Heath Riles BBQ Competition BBQ Rub. This builds savory backbone inside the filling and again on the outside before smoking.
• Heath Riles BBQ Garlic Jalapeño Rub. Adds subtle garlic-forward heat that complements the sausage and fresh jalapeños.
• Chopped Jalapeños. Fresh heat and texture inside every slice.
• Minced Garlic. Rounds out the filling with aromatic depth.
• Thick-Cut Cheddar Cheese. Provides creamy melt throughout the filling.
• Thin-Cut Bacon. One slice per shell, wrapped edge to edge so it renders properly during the cook.
• Heath Riles BBQ Sweet BBQ Sauce. Forms the base of the glaze and provides body and shine.
• Heath Riles BBQ Apple Habanero Glaze. Adds fruity sweetness and a subtle back-end heat that keeps the sauce balanced.

Smoker Setup

These Smoked Shotgun Shells were cooked on the Recteq Flagship 1600.

Fuel: Royal Oak Charcoal & Hickory Blended Pellets

Cooking temperature: 300°F

Pellet grills perform best when the lid stays closed. Once the shells go on the Recteq Flagship 1600, let the cooker maintain steady heat and resist the urge to check too often. Consistent temperature is what allows the bacon to render properly and the pasta to soften evenly.

The Process for Smoked Shotgun Shells

Build the Filling

In a large Mixing Bowl, combine:

• 1 lb lean ground beef
• 1 lb Italian sausage

Season with:

• 1 tablespoon Competition BBQ Rub
• 1 tablespoon Garlic Jalapeño Rub

Add chopped jalapeños, minced garlic, and thick-cut cheddar cheese.

Mix thoroughly in the Mixing Bowl until evenly distributed.

Stuff the Shells

Set up your prep area on a sturdy Cutting Board.

Stuff each manicotti shell from both ends, packing the filling tightly.

Place the filled shells onto a Sheet Pan with Baking Rack.

Wrap in Bacon

Wrap each shell completely with thin-cut bacon and return them to the Sheet Pan with Baking Rack.

If prepping overnight, lightly cover with Aluminum Foil and refrigerate for at least 3–4 hours.

Season and Smoke

Remove the shells from the refrigerator and lightly season the exterior with more Competition BBQ Rub.

Place them directly on the grates of the Recteq Flagship 1600.

Cook for 45 minutes to 1 hour at 300°F.

Start checking internal temperature around the 45-minute mark using the Thermoworks Thermapen ONE. You’re looking for about 180°F in the center of the filling.

Use sturdy Tongs when handling to keep the bacon intact.

Glaze and Finish

In your Mixing Bowl, combine:

• ¾ cup Sweet BBQ Sauce
• 2–3 tablespoons Apple Habanero Glaze

Stir until smooth.

Using a Basting Brush, coat each shell generously.

Return them to the Recteq Flagship 1600 for 3–5 minutes to let the glaze tighten.

Remove carefully with Tongs and allow them to rest before slicing.

The Results

When sliced, these shotgun shells should show:

• Tender pasta with no crunch
• Juicy, well-seasoned filling
• Melted cheese throughout
• Crisp, smoky bacon holding everything together
• A glossy, slightly sticky glaze

The flavor builds in layers — savory from the rub, richness from the sausage, creaminess from the cheese, and sweet heat from the glaze.

Serving Suggestions

These Smoked Shotgun Shells are rich, smoky, and packed with bold flavor, so pairing them with sides that balance that richness takes your spread to the next level. Serve the shells sliced into bite-sized rounds for easy grabbing at tailgates, backyard parties, or game day spreads.

Here are a few perfect companion recipes from the Heath Riles BBQ lineup:

• Easy Classic Coleslaw — A cool, crunchy counterpoint to the smoky, cheesy shells. This classic slaw keeps it simple and refreshing without overpowering the main dish.
• Pit Style BBQ Baked Beans — Rich, savory beans with that deep barbecue flavor everyone loves. They add body and heartiness to your barbecue plate.
• Grilled Corn with Citrus Lime Butter — Bright, buttery corn with citrus notes that brighten every bite. The citrus lime butter cuts through the richness and adds a fresh pop.
• Smoked Mac and Cheese — Creamy, smoky, and indulgent. If your crowd loves cheesy comfort food, this is an unforgettable pairing.

Whether you turn this into a full barbecue plate or keep it casual with friends, these sides work together to balance smoke, creaminess, and brightness — making every bite of your Smoked Shotgun Shells even better.

Slice the shells right before serving so each piece holds together cleanly, then set out the sides for a complete backyard barbecue spread that hits every note.

Storing Leftovers

Store leftovers in an airtight container in the refrigerator for up to 3 days.

Reheat on the Recteq Flagship 1600 at 375–400°F until warmed through to maintain bacon texture. Avoid microwaving.

Final Thoughts

These Smoked Shotgun Shells prove that when you build flavor intentionally and respect the process, simple ingredients can turn into something memorable.

Cooked steady on the Recteq Flagship 1600, fueled by Royal Oak Charcoal & Hickory Blended Pellets, seasoned with Competition BBQ Rub and Garlic Jalapeño Rub, and finished with Sweet BBQ Sauce and Apple Habanero Glaze, this recipe delivers bold flavor and serious visual impact.

If you’re looking for a smoked appetizer that slices clean, eats hearty, and brings backyard barbecue energy to the table, this one deserves a permanent spot in your lineup.

Equipment and Tools

Recteq Flagship 1600, Royal Oak Charcoal & Hickory Blended Pellets, Mixing Bowl, Cutting Board, Tongs, Thermoworks Thermapen ONE, Basting Brush, Sheet Pan with Baking Rack, Aluminum Foil