1-Step 1: Prepare the Meat and Cheese Filling Start by gathering a large mixing bowl and all your ingredients. You’ll want to combine 1 lb ground beef (80/20 blend), 1/2 lb ground pork, 1 cup shredded mozzarella cheese, 8 oz cream cheese, and 1 tbsp BBQ all-purpose seasoning. The cream cheese should be softened to room temperature for easier mixing. Using your hands is the best method for mixing everything thoroughly. Yes, it’s a bit messy, but you’ll get the most even distribution of seasonings and cheeses this way. Work the mixture until all ingredients are fully incorporated and you don’t see any white streaks of cream cheese. The mixture should hold together well when you squeeze it in your hand.

2-Step 2: Stuff the Manicotti Shells Take your raw manicotti pasta shells and begin stuffing them with the meat mixture. Use your fingers to press the filling into each shell, working from both ends to ensure even distribution. You want to fill each shell completely, but avoid overstuffing to the point where the filling is spilling out. The amount of filling per shell should be generous but manageable. A typical box of manicotti contains about 14 shells, and this recipe makes enough filling for all of them with possibly a little leftover. Don’t worry if the shells have small cracks or imperfections; the bacon wrap will help hold everything together during cooking. Some cooks find it easier to use a small spoon or piping bag for this step, but fingers give you the best control over how tightly you pack each shell. Just wash your hands thoroughly before starting and keep a damp towel nearby for cleanup.

3-Step 3: Wrap Each Shell with Bacon Now comes the fun part: wrapping each stuffed shell with a slice of bacon. Take one slice of bacon and spiral it around the shell, starting at one end and working your way to the other. The bacon should overlap slightly to ensure full coverage. Some pasta showing through is perfectly fine; the bacon is there to add flavor and help seal the filling, not create a perfect barrier. Once wrapped, season the outside of each shell with a little extra BBQ all-purpose seasoning. This additional seasoning helps create a flavorful crust as the bacon cooks and renders its fat. Place each wrapped shell on a plate or tray as you finish wrapping them.

4-Step 4: Prepare Your Grill or Smoker Preheat your grill to 300°F using indirect heat. If you’re using a smoker, set it to the same temperature. The indirect heat method is crucial because it allows the pasta to cook through without burning the bacon or charring the outside before the inside is done. If you’re using a gas grill, turn on only one side of the burners and cook on the unlit side. For charcoal grills, push the coals to one side and cook on the opposite side. You want a consistent temperature throughout the cooking process, so monitor your heat carefully. For those without access to a grill or smoker, you can absolutely make these in the oven. Simply preheat your oven to 300°F and use the same cooking time. Place the shells on a wire rack set over a baking sheet to allow air circulation all around, which helps the bacon cook evenly.

5-Step 5: Smoke the Shells Place your stuffed shells on a wire rack positioned on the grill grates. Using a wire rack is important because it keeps the shells elevated and allows heat to circulate all around them. This ensures even cooking and prevents the bottoms from getting soggy or sticking. Smoke the shells for approximately 1 hour at 300°F. You’ll know they’re done when the pasta has softened and the bacon has crisped up nicely. The internal temperature of the meat filling should reach 165°F for food safety. Don’t rush this step; cooking low and slow is what makes the pasta tender without breaking apart. If you find the bacon is browning too quickly, you can move the shells to a cooler part of the grill or reduce the heat slightly. The goal is crispy bacon and soft pasta with fully cooked meat inside.

6-Step 6: Add the BBQ Sauce Glaze During the last 1-2 minutes of cooking, brush approximately 1/4 cup of BBQ sauce over the shells. This quick glaze adds a sticky sweetness and helps caramelize the exterior. The high heat at this stage creates that beautiful, shiny finish that makes these shells so visually appealing. Work quickly during this step, as the sugars in the BBQ sauce can burn if left too long over direct heat. Apply a thin, even coat to each shell and let them cook for just another minute or two. The sauce should bubble slightly and start to set, but not char or turn black.

7-Step 7: Rest and Serve Remove the shells from the heat and let them rest for a few minutes before serving. This resting period allows the juices to redistribute throughout the filling and helps everything hold together better when you cut into them. Serve warm with additional BBQ sauce on the side for dipping if desired. These shotgun shells make an excellent appetizer or main course depending on how many you serve per person. As an appetizer, count on 2-3 shells per person. For a main dish, 4-5 shells per person is a satisfying portion.