Stuffed with sausage, cheese and jalapeños, then wrapped in smoky Kountry Boys Original Bacon , these Shotgun Shells are a bold Texas appetizer built to impress.
Difficulty: Moderate
Prep: 30 minutes
Cook: 90 minutes
Total: 120 minutes
Serves: 7
Ingredients
1 package Kountry Boys Original Bacon
2 tbsp Italian seasoning
1 pound hot Italian sausage
1/2 cup pepperoni, chopped
1 1/2 cups shredded mozzarella
4 tbsp salted butter, melted
1/4 cup grated parmesan cheese
1 cup marinara sauce
Method
Preheat your smoker or oven to 275 degrees.
In a medium bowl, combine sausage, pepperoni and mozzarella. Carefully stuff into the partially cooked manicotti shells. Wrap each shell with one slice of bacon, tucking the ends to secure it.
Top with Italian seasoning and bake for one and a half hours, or until bacon has rendered and the sausage reaches an internal temperature of at least 165 degrees.
Remove shotgun shells and brush with melted butter. Sprinkle with parmesan cheese and let cool for a few minutes before serving with warmed marinara sauce.
Long Description
If you’ve never had Shotgun Shells, you’re in for a wild ride. Jumbo pasta shells get stuffed with a cheesy, spicy mix of Italian sausage and jalapeños, then wrapped in strips of Kountry Boys Original Bacon. Slow smoked or baked, the pasta softens as it cooks, soaking up all that smoky, meaty flavor. It’s tender, cheesy, spicy and smoky — everything Texans love in one bite.
Why You’ll Love This Recipe
Shotgun Shells aren’t just an appetizer — they’re a showstopper. Perfect for tailgates, family cookouts and hunting weekends, these loaded shells are hearty enough to be a meal on their own. The mix of smoky bacon, bold sausage and melty cheese inside tender pasta makes them a guaranteed crowd-pleaser.
And here’s the kicker: once you make them, everyone’s going to ask you for the recipe.
What Makes These Shells Texas-Style?
Bigger, Bolder, Smokier
Everything’s bigger in Texas, and these shells are proof. Forget dainty appetizers — each shell is a handheld powerhouse of smoky, spicy, cheesy flavor that hits like a full meal.
Why Kountry Boys Bacon Makes the Difference
Most shotgun shells start with store-brand bacon that gets lost in the cook. Not here. Using Kountry Boys Original Bacon locks in smoke, crisps up beautifully and adds a salty punch that balances the creamy cheese and bold Italian sausage. Every bite carries that unmistakable flavor of Texas supper tables and backyard grills.
How to Serve Shotgun Shells
- Game Day MVP – The kind of appetizer that keeps the whole crew huddled around the food table
- Backyard BBQ Star – Serve alongside brisket or ribs and watch them disappear
- Hunting Camp Fuel – Fire up the smoker at camp and keep the crew fed all weekend
- Party Showpiece – Line them up on a platter and you’ve got a conversation starter
These aren’t just snacks — they’re the dish everyone remembers.
Customize the Heat Level
Mild Options
Use green bell peppers instead of jalapeños and go heavy on the cheese for a kid-friendly version.
Spicy Options
Keep the jalapeño seeds in, mix in pepper jack cheese or dust shells with crushed red pepper.
Over-the-Top Heat
Swap jalapeños for habaneros or drizzle with hot sauce before serving.
Tips for the Best Results
- Soften the pasta. Parboil shells just a couple of minutes so they don’t crack when you stuff them
- Stuff generously. Fill each shell full — the bigger the bite, the better
- Wrap tight. Overlap bacon ends so they don’t shrink away during cooking
- Smoke low and slow. If using a smoker, go at 250°F for about an hour until bacon is crisp and pasta tender
- Sauce at the end. Brush with barbecue sauce during the last few minutes for a sticky, smoky glaze
Why This Recipe Works
Shotgun Shells combine three things Texans never get tired of — sausage, bacon and cheese. The pasta shell holds everything together, the smoker adds depth and the bacon crisps up like a built-in layer of flavor. It’s fun to make, impressive to serve and easy to customize. That’s why this recipe has exploded in popularity and why it’s here to stay.
Recipe Card
Difficulty: Medium
Prep Time: 25 minutes
Cook Time: 60 minutes
Total Time: 1 hour 25 minutes
Serves: 6–8
Ingredients
- 1 lb Italian sausage, cooked and crumbled
- 12 jumbo pasta shells
- 1/2 cup shredded cheddar cheese
- 1/2 cup shredded Monterey Jack cheese
- 2 fresh jalapeños, diced
- 1/2 cup cream cheese, softened
- 12 slices Kountry Boys Original Bacon
- 1/2 cup barbecue sauce (optional)
Method
- Preheat smoker or oven to 250°F.
- Boil pasta shells for 2–3 minutes, just until slightly softened. Drain and cool.
- Cook Italian sausage, then mix with cheddar, Monterey Jack, cream cheese and diced jalapeños.
- Stuff each shell with sausage mixture.
- Wrap each shell with one strip of Kountry Boys Bacon, securing ends underneath.
- Place shells seam side down on smoker rack or baking sheet.
- Smoke or bake for 60 minutes, until bacon is crisp and pasta is fully cooked.
- Brush with barbecue sauce in the last 5 minutes, if desired.
- Serve hot and enjoy.
Bringing Texas Flavor to Your Table
At Kountry Boys, we believe food should be as bold as the people who gather around it. These Shotgun Shells prove that a little creativity — and a lot of bacon — can turn simple ingredients into a show-stopping dish.
Whether you’re feeding the hunting camp, tailgating with friends or firing up the backyard pit, this recipe delivers the smoky, cheesy, spicy punch that makes Texas cooking unforgettable.
Try more bold recipes like our Lone Star Sausage Egg Rolls or Sausage and Corn Fritters.