1-First Step: Get everything ready Start by gathering all ingredients and tools so the process moves smoothly. You will need a large mixing bowl, a spoon, a baking sheet, tongs, a smoker, and a brush for the barbecue sauce. Preheat your smoker to 250 degrees Fahrenheit so it is ready when the shells are stuffed and wrapped. This recipe works best with uncooked manicotti shells because they are easier to stuff. Since the filling is mixed raw, the meat cooks slowly inside the pasta and bacon while it smokes. That is part of what gives smoked shotgun shells their rich texture and deep flavor.

2-Second Step: Mix the filling Add the ground beef, hot Italian sausage, diced onion, sharp cheddar cheese, cream cheese, jalapeno, seasoning, garlic powder, black pepper, red pepper flakes, and one-third cup barbecue sauce to a large bowl. Mix everything well, but do not cook the meats first. The raw filling cooks fully in the smoker, and that helps keep the shells juicy. For the best texture, mix until the cheeses and seasonings are spread evenly through the meat. If you want a milder version, skip the jalapeno and red pepper flakes and use mild Italian sausage instead. If you like bolder flavor, a spoonful of extra barbecue sauce can be mixed in, but keep the filling thick enough to stay inside the shells.

3-Third Step: Stuff the manicotti shells Take one uncooked manicotti shell at a time and gently stuff it from both ends. Try not to force the filling too quickly, because the shells can crack if they are handled roughly. A chopstick or the handle of a wooden spoon works well for pressing the filling into the center. Do your best to avoid air pockets. A tightly packed shell cooks more evenly and holds together better once the bacon wraps around it. Place each stuffed shell on a baking sheet while you finish the rest. Be gentle here. Dry manicotti shells are much easier to handle, but they can still crack if you rush the stuffing process.

4-Fourth Step: Wrap with bacon and sauce Wrap each stuffed shell with bacon slices, covering the ends as much as possible. Some shells may need two pieces of bacon, especially if the bacon is thin or the shell is full. The bacon helps lock in moisture and gives the dish its signature smoky, salty flavor. Brush additional barbecue sauce over both sides of the wrapped shells. Use your favorite barbecue sauce flavor, whether that is sweet, smoky, tangy, or spicy. The sauce will caramelize as the shells smoke and give them a glossy finish.

5-Fifth Step: Smoke until the bacon starts to render Place the wrapped shells directly on the grill grates in the smoker. Smoke them for 60 minutes at 250 degrees Fahrenheit. This first stage helps the bacon begin to cook and allows the pasta to start softening. Choose your favorite wood for smoke flavor. Hickory, apple, pecan, cherry, and mesquite all work well depending on the flavor you like. If your smoker runs a little warm or cool, stay in the range of 225 to 250 degrees for the best results.

6-Sixth Step: Flip, sauce again, and finish After the first hour, flip the shells carefully. Add more barbecue sauce if needed, then keep smoking for another 60 minutes or until the bacon is crispy and the filling is cooked through. Total cook time is about 2 hours, and the full recipe takes about 2 hours and 35 minutes including prep. When the shells are done, remove them from the smoker and let them rest for a few minutes before serving. This short rest helps the juices settle so they are easier to eat. Serve them warm with extra barbecue sauce for dipping if you like.