Pit-Smoked Power Shells

Welcome to your new favorite Traeger recipe! These incredible Smoked Shotgun Shells are an absolute game-changer for any grilling enthusiast. Imagine tender manicotti shells, generously filled with a savory blend of pepper jack cheese and ground pork sausage, expertly wrapped in crispy bacon, and then lavishly drenched in rich, tangy Kansas City BBQ sauce. Smoked to perfection on your Traeger, these flavorful bites offer an irresistible combination of textures and tastes that will have everyone clamoring for more.

And for those who believe you can never have too much cheese, an optional addition of melty string cheese takes these shotgun shells to a new level of gooey, cheesy delight. Whether you’re preparing for a lively tailgate party, a casual weekend cookout, or simply craving a unique weeknight meal with a smoky twist, these BBQ shotgun shells are guaranteed to impress. They perfectly embody the spirit of outdoor cooking, delivering an unforgettable flavor experience that’s both comforting and exciting. Get ready to fire up your smoker and dive into this mouthwatering adventure!

While these versatile tubes of pasta are a staple at my tailgating events, they are equally fantastic for a relaxed mid-week dinner. The beautiful smokiness infused by the Traeger transforms them into a hearty, satisfying meal. Pair these savory smoked shotgun shells with some crispy air fryer baked potatoes or perfectly seasoned grilled potato wedges for a balanced and unbelievably delicious plate that will have you reaching for seconds, and even thirds!

Beyond being a show-stopping appetizer for game day or a fun family dinner, these smoked shotgun shells are also perfect for meal prepping. You can prepare them ahead of time and simply reheat them when you’re ready to enjoy that smoky, cheesy goodness. From feeding a crowd of hungry kids to wowing your friends before a big sporting event, this recipe is incredibly adaptable and always a crowd-pleaser. Just be warned: they tend to disappear in minutes, so make extra!

💪 Why These Traeger Smoked Shotgun Shells Are a Must-Try

This Smoked Shotgun Shells recipe isn’t just another dish; it’s a culinary experience designed for maximum flavor and enjoyment. Here’s why it will quickly become one of your go-to Traeger recipes:

• Uniquely Delicious Flavor Profile: The combination of tender pasta, spicy pepper jack cheese, savory sausage, crisp bacon, and sweet Kansas City BBQ sauce creates an explosion of flavors that is truly distinctive. The optional string cheese adds another layer of delightful richness, making each bite an indulgence.
• Perfectly Balanced Textures: You get the al dente bite of perfectly cooked pasta, the satisfying chew of flavorful sausage, the creamy melt of cheese, and the irresistible crispiness of bacon, all brought together by the smooth, caramelized BBQ glaze.
• Beginner-Friendly with Impressive Results: Don’t let the sophisticated flavor fool you; the steps for making these smoked shotgun shells are straightforward and easy to follow. Even novice grillers can achieve professional-level results, making it a fun and rewarding cooking project.
• Infused with Authentic Smoke Flavor: Cooking on the Traeger imbues these shotgun shells with a deep, smoky aroma and taste that you simply can’t replicate indoors. The pellets slowly smoke the ingredients, creating a complex flavor that is the hallmark of true BBQ.
• Achieve Perfect Pasta Every Time: Pre-cooking the manicotti shells ensures they reach that ideal al-dente texture, preventing them from being crunchy or undercooked. For those in a hurry, you can start with raw pasta, but the pre-boiling method guarantees superior results.
• Versatile Pasta Options: No manicotti? No problem at all! This recipe thoughtfully provides an alternative preparation using readily available lasagna noodles, ensuring you can still enjoy this fantastic dish regardless of what’s in your pantry.
• Minimal Equipment Needed: You don’t need a kitchen full of gadgets to bring these smoked shotgun shells to life. A Traeger smoker, a large mixing bowl, and a pot for boiling pasta are essentially all you need, making it an accessible recipe for everyone.
• Make-Ahead Convenience: These shotgun shells are fantastic for preparing in advance. Assemble them, store them, and smoke them when you’re ready, making entertaining or busy weeknights much easier.

Each element of this recipe has been carefully considered to deliver a memorable and thoroughly enjoyable smoked dish that you’ll want to make again and again.

🍽 Essential Ingredients for Smoked Shotgun Shells

Crafting these delectable smoked shotgun shells requires a thoughtful selection of ingredients that build layers of flavor and texture. Here’s a detailed look at what you’ll need to create this BBQ masterpiece. For precise measurements, please refer to the comprehensive recipe card below.

• Manicotti Shells: These large, tubular pasta shells are the classic base for shotgun shells, perfect for stuffing. However, if manicotti is hard to find, don’t fret! Lasagna noodles are an excellent alternative. Simply boil them until pliable, allowing you to easily roll them around the savory filling.
• Ground Pork Sausage: The heart of the filling, ground pork sausage provides a rich, savory foundation. Opt for a sausage with a slightly higher fat content (e.g., 80/20) if possible, as it will remain moist and exceptionally flavorful during the long smoking process. You can choose mild or spicy sausage based on your preference.
• Pepper Jack Cheese, shredded: This cheese is paramount for adding a creamy texture and a delightful spicy kick to your shotgun shells. Pepper jack melts beautifully, offering a buttery richness with just enough heat to elevate the entire dish without overpowering other flavors.
• Spiceology Hickory Peach Porter Rub: This unique, beer-infused dry rub is a secret weapon, bringing notes of chocolate, caramel, and toffee that perfectly complement the sausage and bacon. It enhances the smoky flavor and adds incredible depth. If you don’t have this specific rub, any sweet and savory BBQ rub with a hint of smoke would be a great substitute.
• Salt and Pepper: Essential seasoning to taste, ensuring the sausage mixture is perfectly balanced. Always adjust according to your preference.
• Thin-Cut Bacon: The bacon wrap is crucial for two reasons: it locks in moisture, keeping the pasta and sausage tender, and it crisps up beautifully on the smoker, adding an irresistible texture and smoky bacon flavor. Thin-cut bacon is preferred because it’s more pliable and stretches easily to fully cover the shells, ensuring uniform cooking and crispiness. Thick-cut bacon tends to be less flexible and might not wrap as snugly.
• Kansas City-Style BBQ Sauce: This iconic sauce is characterized by its sweet, tangy, and smoky profile, often featuring molasses and ketchup. It creates a glorious glaze as it caramelizes on the smoker, providing that classic BBQ flavor that binds all the components together perfectly. You can use your favorite brand or even a homemade version.
• String Cheese (optional): For an extra layer of gooey indulgence and that epic cheese pull! String cheese works particularly well when using lasagna noodles, as the flatter surface provides ample room to wrap the sausage mixture around a whole stick, ensuring melty cheese in every bite. While it’s optional, it’s highly recommended for cheese lovers!

👨‍🍳 Crafting Your Smoked Shotgun Shells: A Step-by-Step Guide

Making these smoked shotgun shells is a surprisingly straightforward process that yields incredibly rewarding results. This guide provides a detailed overview, but for the most precise, step-by-step instructions, be sure to check the printable recipe card at the bottom of this page. Remember, if manicotti shells are unavailable, lasagna noodles make a fantastic alternative with slightly modified instructions.

1. Prepare the Pasta Water: Begin by filling a large pot with generously salted water and bring it to a rolling boil on your stovetop. This is crucial for properly cooking the pasta.
2. Preheat Your Traeger Smoker: While the water heats, preheat your Traeger smoker to 225°F (107°C). Use your favorite hardwood pellets; I personally love these Traeger Signature Blend pellets for their balanced smoke flavor that complements everything from pork to poultry.
3. Prepare the Sausage Mixture: In a large mixing bowl, combine your ground pork sausage, shredded pepper jack cheese, Spiceology hickory peach porter rub (or your preferred BBQ rub), and a pinch of salt and pepper. Mix thoroughly with your hands until all ingredients are evenly distributed, but avoid overmixing to keep the sausage tender.

Preparing Manicotti Shells

1. Boil Manicotti Shells: Carefully add the manicotti shells to the boiling salted water. Boil them for approximately 3-4 minutes, or until they are slightly soft and pliable but still firm enough to hold their shape without collapsing. They should be al dente, not fully cooked. Drain them and rinse with cold water to stop the cooking process and make them easier to handle.
2. Stuff and Wrap: Using a spoon or a piping bag (for easier stuffing), fill each pre-boiled manicotti shell generously with the prepared sausage and cheese mixture. Once stuffed, wrap each shell tightly with 1 to 2 slices of thin-cut bacon, ensuring the entire pasta shell is covered. This coverage is key to preventing the pasta edges from drying out and becoming crispy during smoking.

Preparing Lasagna Noodles

1. Boil Lasagna Noodles: Submerge the lasagna noodles in the boiling salted water. Cook them for about 10-11 minutes, or until they are flexible and easy to roll but still slightly firm. Drain them and rinse with cold water.
2. Stuff and Wrap: Divide the sausage mixture into equal portions (about 12). If using string cheese, slice each stick lengthwise in half. Form each sausage portion into a flat patty, place a piece of string cheese in the center (if desired), and then shape the sausage around the cheese to create a log. Lay a cooked lasagna noodle flat, place a sausage log at one end, and carefully roll the noodle around the sausage log. Finish by wrapping the stuffed noodle with 1 to 2 slices of thin-cut bacon, ensuring complete coverage.

Smoking Your Shotgun Shells

1. Initial Smoke: Carefully place all the bacon-wrapped shotgun shells directly onto the grates of your preheated Traeger smoker. Smoke them for 1 hour at 225°F (107°C). This initial smoking phase allows the flavors to meld and the bacon to start rendering.
2. Apply BBQ Sauce: After 1 hour, open the smoker and generously coat all sides of each shotgun shell with your Kansas City-style BBQ sauce. Don’t be shy here – go all in with the sauce! A good coating of BBQ sauce is essential for moisture, flavor, and creating that beautiful caramelized glaze. Use a basting brush to ensure even coverage.
3. Continue Smoking to Perfection: Close the smoker and continue cooking for another hour, or until the internal temperature of the sausage reaches 160°F (71°C) when checked with an instant-read thermometer, and the BBQ sauce has caramelized to a sticky, beautiful glaze.
4. Serve Immediately: Once cooked through and perfectly glazed, carefully remove the smoked shotgun shells from the Traeger. Let them rest for a few minutes before serving to allow the juices to redistribute and the cheese to set slightly. Serve hot and enjoy every smoky, savory bite!

Following these steps will ensure your smoked shotgun shells are a resounding success, delivering an unforgettable experience of smoky, cheesy, bacon-wrapped goodness.

😉 Pro Tips for Perfect Smoked Shotgun Shells

Achieving truly exceptional smoked shotgun shells goes beyond just following the steps. These expert tips will help ensure your dish is moist, flavorful, and perfectly cooked every single time:

• Don’t Skip Pre-Boiling the Pasta: This is a crucial step! For manicotti shells, a quick 3-4 minute boil until slightly softened prevents them from being tough or crunchy after smoking. For lasagna noodles, boil them until they are flexible enough to roll easily (about 10-11 minutes). This ensures an ideal al-dente texture that perfectly complements the savory filling.
• Generous BBQ Sauce Application is Key: After the initial smoking period, be incredibly generous when slathering your shotgun shells with BBQ sauce. Ensure every side and end is thoroughly coated. This thick layer of sauce acts as a protective glaze, locking in moisture and creating a delicious, caramelized crust, preventing the pasta and meat from drying out.
• Maximize Bacon Coverage: The bacon wrap isn’t just for flavor; it’s essential for moisture retention. Use thin-cut bacon and wrap each shell tightly, making sure no raw pasta is exposed. The bacon slowly renders, basting the pasta and sausage as it cooks, resulting in a wonderfully moist interior and crispy exterior.
• Consider Chilling for Easier Handling (Optional): While not strictly necessary, some pitmasters prefer to assemble the shotgun shells and then chill them in the refrigerator for 30 minutes to an hour before smoking. This can help the sausage mixture set and make the shells firmer and easier to handle when transferring them to the Traeger.
• Spice It Up with Cheese: If you’re a fan of serious heat, select a pepper jack cheese with a higher concentration of spicy peppers. You can also mix in a pinch of cayenne pepper or red pepper flakes directly into the sausage mixture for an extra fiery kick.
• Monitor Internal Temperature: Always use a reliable instant-read thermometer to ensure the sausage reaches an internal temperature of 160°F (71°C) for food safety. This also helps prevent overcooking, which can lead to dry sausage.
• Experiment with Rubs and Sauces: While the Spiceology Hickory Peach Porter Rub and Kansas City BBQ sauce are fantastic, don’t hesitate to experiment! Try different BBQ rubs (spicy, smoky, sweet) and various regional BBQ sauces (Carolina Gold, Texas-style, Alabama white) to discover your favorite flavor combinations.

❓ Frequently Asked Questions About Smoked Shotgun Shells

🎁 The Grand Finale: Your Next Favorite BBQ Recipe

There you have it – the ultimate guide to creating mouthwatering smoked shotgun shells that are guaranteed to be a hit at any gathering. Whether you’re pulling out your trusty Traeger for a new grilling adventure or simply looking to elevate your next tailgating party, this recipe is perfectly poised to fit the bill.

Each bite delivers an exquisite blend of sweet and smoky flavors, a satisfying crunch from the perfectly rendered bacon, and an incredibly moist, savory interior. This knockout recipe promises to please not just your taste buds, but your entire family and every guest fortunate enough to try them. So go ahead, fire up that smoker, and get ready to experience a dish that embodies the very best of BBQ!

 🛠 Recommended Tools and Equipment

Having the right tools can make all the difference in your grilling experience. Here are some essential items that will help you master these smoked shotgun shells and other delicious BBQ recipes:

• Traeger Pellet Grill: A high-quality pellet grill like the Traeger Timberline 1300 is an absolute game-changer. Its massive cooking surface provides ample room for cooking a feast, and the consistent temperature control ensures perfect smoking every time. Don’t forget to stock up on quality Traeger signature pellets for that authentic smoky flavor.
• Instant-Read Thermometer: A ThermoWorks Thermapen One is an absolute must-have for any serious cook. It provides incredibly fast and accurate temperature readings, ensuring your meats are cooked to perfection and safe to eat every time.
• High-Quality Cutting Board: Every BBQ enthusiast and home chef needs a durable and spacious cutting surface. A John Boos Maple Butcher Block is a professional-grade option that is not only functional but also a beautiful addition to any kitchen.
• BBQ Basting Brush: For perfectly slathering on that delicious BBQ sauce, an OXO BBQ basting brush is ideal. Its silicone bristles ensure even coverage and are easy to clean, making sauce application a breeze.

🤤 More Awesome Traeger & Air Fryer Recipes

If you loved these smoked shotgun shells, you’ll definitely want to explore these other fantastic recipes to expand your grilling and air frying repertoire:

• For the perfect side, these air fryer potato wedges are incredibly crisp and make a great addition to any BBQ spread. Or try this indulgent variation: air fryer wedges with a cheese crust.
• Craving more cheesy, smoky goodness? This recipe for Traeger smoked potatoes au gratin is wonderfully creamy and cheesy, pairing perfectly with the robust flavors of smoked shotgun shells.
• We all need more vegetables in our lives, especially when they’re this delicious! Explore options like tender air fryer cauliflower, perfectly cooked Traeger smoked asparagus, or a flavorful air fryer butternut squash with sage brown butter.
• No BBQ is complete without classic sides, and cowboy baked beans are an absolute staple at my summer cookouts. They’re rich, hearty, and packed with flavor.

💬 Tell Me What You Think!

I would absolutely love to hear from you! If you tried out this incredible recipe for smoked shotgun shells, please take a moment to leave a comment below and let me know how much you enjoyed it. Your feedback is truly appreciated and helps other grillers discover new favorites.

Even better, snap a picture of your culinary creation and share it on your favorite social media platform! Be sure to tag me at @alicensetogrill and let me know how you liked it! I can’t wait to see your delicious results!

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