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Chorizo Stuffed Shotgun Shells

Weber Test Kitchen

  • People

    Serves 14 to 28

  • Prep Time

    20 mins

  • Grilling Time

    1:10 h

Ingredients
Instructions

the Ingredients

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  • Completed step 12 ounces Mexican-style chorizo (see recipe tips)
  • Completed step ½ pound 80/20 ground beef
  • Completed step 2 cups grated Monterey Jack cheese
  • Completed step 4 ounces diced green chiles
  • Completed step 8 ounces manicotti shells
  • Completed step 1 pound regular cut bacon (see recipe tips)
  • Completed step 1 cup your favorite thick and sweet BBQ sauce

Special Equipment

Take Your Grilling Anywhere

FIRE UP YOUR GRILL

Instructions

The bacon-wrapped shotgun shell has quickly become a must-have recipe for any BBQ enthusiast, and it’s easy to see why. The process for making them is unexpected––the moisture from the raw sausage and raw bacon first work to soften the uncooked pasta shell, then 1 hour of low and slow smoke adds deep smoky flavor, while the final roasting temperature gives it caramelization and color.
  • Combine the beef, chorizo, cheese, and chiles in a large mixing bowl and use two forks to thoroughly mix it together.
  • Pinch off small pieces of the mixture and use your fingers to stuff it into each of the shells (see recipe tip), being sure that there are no air pockets in the shell.
  • Wrap each shell with the bacon, doing your best to completely cover the shells in the bacon, as any part of the shell that’s exposed will end up a little too chewy.
  • Place the shells in a lidded container and refrigerate, covered, overnight. This will help soften the pasta shell before it bakes.
  • Prepare the grill for Indirect Very Low cooking (180°–250°F) using a mini-Minion method. Add a few wood chunks to the coals for smoke flavor.
    Set the grill to the SmokeBoostTM setting.
    Prepare the grill for Indirect Very Low cooking (180°–250°F). Add a handful of wood chips to a smoker box and place it over the lit burner and wait for smoke to form.
  • Place the shells on the grill and cook, with the lid closed for 1 hour.
  • Remove the shells from the grill, and open up the vents to increase the temperature to 400°F.
    Remove the shells from the grill and increase the temperature to 400°F.
    Remove the shells from the grill, remove the smoker box, and increase the temperature to 400°F.
  • Brush the shells all over with the BBQ sauce, return them to the grill, and cook for 5 minutes. Flip the shells and continue cooking until the sauce has caramelized and charred in places, about 5 minutes longer
  • Let the shells rest for at least 5 minutes before serving.

Recipe Tips

1. Mexican chorizo is a raw pork sausage that needs to be cooked before serving, unlike Spanish-style chorizo that is dried and cured. You want the raw style for this recipe. 2. We’ve tried several different tools and tricks to stuff these shells, and nothing seems to work quite as well as a clean (or gloved) pair of hands. It can seem a little tedious, but it’ll pay off in the end. 3. While this recipe wouldn’t be bad with thick-cut bacon, 1 lb of thick-cut bacon won’t have enough slices to cover all of the manicotti shells, so buy an extra pound if you want to make the substitution. Just avoid center-cut bacon, as the strips are too short.

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