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This BBQ Shotgun Shells recipe transforms ordinary manicotti into extraordinary meat-filled, bacon-wrapped delights that disappear faster than you can say barbecue. The combination of beef and sausage stuffed into pasta shells, wrapped in crispy bacon, and brushed with tangy BBQ sauce creates an unforgettable appetizer experience that bridges the gap between pasta and barbecue.
These shotgun shells have become my go-to crowd pleaser whenever I host backyard gatherings. The first time I made them for a Super Bowl party, they vanished within minutes and three different guests asked for the recipe before halftime even started.
Ingredients
- Ground beef: Creates the hearty base of the filling. Look for 80/20 lean to fat ratio for best flavor.
- Italian sausage: Adds complexity and seasoning. Choose mild or hot depending on your preference.
- Colby Jack cheese: Melts beautifully and adds a creamy richness. Sharp cheddar works equally well.
- Cream cheese: Creates a smooth texture and helps bind everything together. Ensure it's room temperature.
- Barbecue sauce: Provides sweet and tangy flavor. Choose your favorite style from Kansas City sweet to Carolina vinegar based.
- Jalapeños: Add a welcome kick of heat. Keep seeds for extra spice or remove for milder flavor.
- Manicotti shells: Create the perfect vessel. Larger than traditional pasta for maximum filling.
- Thick cut bacon: Wraps everything in smoky goodness. The thicker cut prevents burning while cooking.
Step-by-Step Instructions
- Prepare the Pasta:
- Boil manicotti shells for exactly 3 minutes only. This partial cooking is crucial as they will continue cooking with the filling. Rinse immediately with cold water to stop the cooking process and separate them carefully to prevent sticking. The shells should be firm enough to stuff without tearing.
- Create the Filling:
- Combine ground beef and Italian sausage thoroughly using your hands for even distribution. Add shredded cheese, room temperature cream cheese, half cup of BBQ sauce, minced jalapeños, and all seasonings. Mix until well incorporated but avoid overworking the meat. The mixture should hold together but still be loose enough to stuff into the shells.
- Stuff the Shells:
- Take a generous portion of meat mixture and carefully push it into one end of each manicotti shell. Work the filling through the entire length using your fingers or a small spoon, ensuring there are no air pockets. The filling should be tightly packed but not so full that it splits the shell. Fill from one end for best results.
- Wrap with Bacon:
- Stretch each piece of thick cut bacon slightly before wrapping around the filled shell in a spiral pattern, overlapping slightly with each turn. Secure the ends by tucking them under previous wraps or using toothpicks if necessary. The bacon should completely cover the shell for even cooking and flavor infusion.
- Cook to Perfection:
- Choose your preferred cooking method and follow the specific temperature and timing guidelines. The key indicator for doneness is when the internal temperature reaches 160°F and the bacon develops a beautiful crispy exterior. Brush with BBQ sauce multiple times during cooking for layers of flavor development.
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My personal secret for these shotgun shells is adding a tablespoon of bourbon to the BBQ sauce before brushing it on. I discovered this trick when I was low on sauce one evening and needed to stretch it with something from my cabinet. The bourbon adds a subtle depth that complements the smokiness of the bacon perfectly.
Make Ahead Tips
These shotgun shells can be prepared up to the wrapping stage and refrigerated for up to 24 hours before cooking. Simply stuff the shells, wrap with bacon, and store covered in the refrigerator. This makes them perfect for entertaining since all the prep work can be done the day before. When ready to cook, brush with BBQ sauce and follow your preferred cooking method. The flavors actually develop nicely with a rest in the refrigerator.
Scaling The Recipe
While this recipe makes about 18 20 shotgun shells depending on your manicotti size, it scales beautifully for larger crowds. The filling can be doubled without any adjustments to ratios, and the shells can be cooked in batches if using an air fryer or small grill. For very large gatherings, consider assigning each batch to a different cooking method if you have multiple appliances available. This strategy helps get everything to the table hot and fresh without extended cooking times.
Flavor Variations
The basic recipe is wonderfully adaptable to different flavor profiles. For a Tex Mex version, substitute pepper jack cheese, add taco seasoning to the meat, and use salsa instead of BBQ sauce. For an Italian twist, use all Italian sausage, add Italian herbs, and substitute marinara for the BBQ sauce. You can even create an Asian inspired version using hoisin instead of BBQ sauce and adding ginger and green onions to the meat mixture. Each variation maintains the core technique while delivering a completely different flavor experience.
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Frequently Asked Questions
- → Can I prepare BBQ Shotgun Shells ahead of time?
Yes, you can assemble them in advance, refrigerate for up to 24 hours, and cook when ready. Be sure to check the bacon's crispiness before serving.
- → What type of cheese works best?
Colby Jack or sharp cheddar cheese adds delicious flavor, but you can also experiment with mozzarella or pepper jack for variety.
- → How do I keep the manicotti shells from breaking?
Boil the shells for only three minutes and handle them gently while stuffing to prevent cracking or collapsing.
- → Can I make these spicier?
Add more jalapeños, include the seeds, or mix in some cayenne pepper to the meat filling for extra spice.
- → Is liquid smoke necessary for the flavor?
Liquid smoke is optional but adds a smoky depth, especially if you're cooking them in the oven or air fryer rather than on a grill or smoker.
- → How do I reheat leftovers?
Reheat leftovers in the oven or air fryer to crisp up the bacon while warming the filling evenly.