Smoked Shotgun Shells Recipe with Savory Stuffing

The beauty of smoked shotgun shells lies in their perfect marriage of familiar comfort food with bold smoky flavors. Unlike traditional baked stuffed shells, these gems spend time in your smoker, absorbing that distinctive wood-fired essence while the cheese melts to perfection and the pasta develops a slightly firmer, more satisfying texture. What makes this recipe particularly special is how the smoking process intensifies every flavor – from the rich Italian sausage to the creamy cheese blend – while creating an almost crispy exterior that gives way to molten, savory filling. The visual impact alone makes them perfect for entertaining, but the taste will keep everyone coming back for seconds.

Ingredients List

For the Pasta Shells:

• 20-24 jumbo pasta shells (conchiglie)
• 1 tablespoon olive oil
• 1 teaspoon salt for pasta water

For the Savory Stuffing:

• 1 pound Italian sausage (mild or hot, based on preference)
• 1 pound ground beef (80/20 blend)
• 1 medium yellow onion, finely diced
• 3 cloves garlic, minced
• 1 cup ricotta cheese
• 1 cup shredded mozzarella cheese (divided)
• ½ cup grated Parmesan cheese
• 1 large egg, beaten
• 2 tablespoons fresh parsley, chopped
• 1 teaspoon Italian seasoning
• ½ teaspoon black pepper
• ½ teaspoon salt

For the Wrapping:

• 12-15 strips of bacon (thin-cut works best)
• Your favorite BBQ sauce for glazing

Substitution Options:

• Gluten-free: Use gluten-free jumbo shells
• Dairy-free: Substitute with cashew ricotta and dairy-free mozzarella
• Leaner option: Use ground turkey instead of beef
• Vegetarian: Replace meat with finely chopped mushrooms and bell peppers

Timing

Total Time: 3 hours 30 minutes

• Prep Time: 45 minutes
• Smoking Time: 2 hours 45 minutes

Time Management Tips:
Cook your pasta shells the night before and store them in the refrigerator. This prevents them from becoming mushy during the smoking process. The meat mixture can also be prepared a day ahead, making assembly day much smoother. Start your smoker while you’re stuffing the shells – by the time you finish wrapping them in bacon, your smoker will be perfectly preheated.

How to Make It

1. Prepare the Pasta Foundation

Cook the jumbo shells in salted boiling water for exactly 2 minutes less than the package directions suggest. They should be firm to the touch since they’ll continue cooking in the smoker. Drain carefully and toss with olive oil to prevent sticking. Lay them out on a baking sheet and let them cool completely.

2. Create the Savory Filling

In a large skillet over medium-high heat, brown the Italian sausage and ground beef together, breaking them into small, uniform pieces. The key here is getting a nice caramelization on the meat without overcooking it. Add the diced onion and garlic during the last 3 minutes of browning. Drain excess fat and let the mixture cool for 10 minutes.

3. Mix the Cheese Blend

In a large mixing bowl, combine the ricotta cheese, ¾ cup of mozzarella, Parmesan cheese, beaten egg, parsley, and seasonings. Fold in the cooled meat mixture until everything is evenly distributed. The mixture should be moist but not wet.

4. Stuff and Wrap Each Shell

Using a small spoon or your hands, carefully stuff each shell with the meat and cheese mixture. Don’t overpack them – they should be full but not bursting. Wrap each stuffed shell with a strip of bacon, starting at one end and spiraling around. Secure with toothpicks if needed.

5. Set Up Your Smoker

Preheat your smoker to 275°F using your preferred wood chips. Apple or cherry wood works beautifully with pork and cheese, providing a mild, sweet smoke that won’t overpower the dish. Hickory adds a stronger flavor if you prefer more intensity.

6. Smoke to Perfection

Place the bacon-wrapped shells on the smoker grates, leaving space between each one for proper air circulation. Smoke for 2 hours, then brush each shell with BBQ sauce. Continue smoking for another 30-45 minutes until the bacon is crispy and the internal temperature reaches 165°F.

7. Final Touch

During the last 10 minutes, sprinkle the remaining mozzarella cheese on top of each shell. This creates a beautiful, bubbly finish that’s absolutely irresistible.

Nutritional Information

Each smoked shotgun shell contains approximately:

• Calories: 380-420
• Protein: 28-32 grams
• Carbohydrates: 18-22 grams
• Fat: 22-26 grams
• Fiber: 1-2 grams

These shells provide excellent protein content from the combination of meats and cheeses. The ricotta contributes calcium and phosphorus for bone health, while the Italian sausage and ground beef supply iron and B vitamins. Keep in mind that nutritional values may vary based on specific ingredient brands and preparation methods.

Healthier Alternatives for the Recipe

Lower Calorie Version: Use lean ground turkey instead of beef and turkey Italian sausage. Substitute part-skim ricotta and reduce-fat mozzarella to cut calories by approximately 25% per serving.

Gluten-Free Adaptation: Simply swap regular pasta shells for gluten-free versions. Tinkyada and Barilla make excellent gluten-free jumbo shells that hold up well during smoking.

Reduced Sodium Option: Choose low-sodium Italian sausage and reduce the added salt in the mixture. Use fresh herbs instead of Italian seasoning blend to control sodium content better.

Vegetarian Version: Replace the meat mixture with sautéed mushrooms, bell peppers, and zucchini. Add chopped walnuts for extra protein and texture. Use turkey bacon or omit the bacon wrapping entirely.

Serving Suggestions

Present these smoked shotgun shells on a rustic wooden platter with fresh herbs as garnish. They pair beautifully with a crisp Caesar salad and garlic bread. For beverages, consider a medium-bodied red wine like Chianti or a cold beer – the smoky flavors complement both perfectly.

For special occasions, serve 2-3 shells per person as a main course, or cut them in half for appetizer portions. They’re stunning alongside grilled vegetables or a simple arugula salad dressed with lemon vinaigrette.

Common Mistakes to Avoid

Overcooking the Pasta: Remember that the shells will continue cooking in the smoker. Undercooked pasta prevents mushy results.

Overstuffing: Resist the urge to pack too much filling into each shell. Overstuffed shells often burst during smoking and create a mess.

Skipping the Rest Period: Let the meat mixture cool before adding to the cheese blend. Hot meat can cause the cheese to become grainy and separate.

Temperature Fluctuations: Maintain consistent smoker temperature throughout the cooking process. Large temperature swings can result in unevenly cooked shells.

Storing Tips for the Recipe

Refrigerator Storage: Store leftover smoked shotgun shells in an airtight container for up to 3 days in the refrigerator. The flavors actually improve overnight as they meld together.

Freezer Storage: These shells freeze beautifully for up to 3 months. Wrap individually in plastic wrap, then store in freezer bags. Thaw overnight in the refrigerator before reheating.

Reheating Instructions: For best results, reheat in a 350°F oven for 15-20 minutes until heated through. Microwave reheating works but may make the bacon less crispy.

Make-Ahead Tips: Assemble the shells completely and refrigerate up to 24 hours before smoking. This actually helps the flavors develop and makes the cooking day much easier.

Conclusion

These smoked shotgun shells represent everything wonderful about outdoor cooking – they’re impressive enough for special occasions yet comforting enough for family dinners. The combination of smoky bacon, creamy cheese filling, and perfectly cooked pasta creates a dish that’s both familiar and exciting. Don’t be surprised if this recipe becomes your go-to crowd-pleaser for gatherings and barbecues. Give them a try at your next cookout, and watch as they disappear faster than you can make them. Share your variations and results – every pitmaster adds their own special touch to make this recipe uniquely their own.

FAQs

Can I make smoked shotgun shells without a smoker?
Absolutely! Use your oven at 300°F and add liquid smoke to the meat mixture for that smoky flavor. Cook for about 45 minutes until the bacon is crispy and cheese is melted.

What if my pasta shells break during stuffing?
Don’t worry about a few cracks – the bacon wrapping will hold everything together. Cook a few extra shells as backups, and save broken ones for a delicious cook’s snack.

How do I prevent the cheese from leaking out?
Make sure your meat mixture has cooled completely before adding cheese, and don’t overstuff the shells. The beaten egg in the mixture helps bind everything together.

Can I prepare these ahead for a party?
Yes! Assemble them completely up to 24 hours in advance. Keep refrigerated and add about 15 minutes to the smoking time since they’ll start cold.

What wood chips work best for this recipe?
Apple and cherry provide mild, sweet smoke that complements the cheese perfectly. Hickory works if you prefer stronger smoke flavor, but use sparingly to avoid overpowering the dish.

How do I know when they’re done?
The bacon should be crispy and golden, and the internal temperature should reach 165°F. The cheese will be bubbly and lightly browned on top.

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