Mix softened cream cheese and shredded cheddar in a bowl until smooth. Divide evenly among the 24 jalapeño halves, filling each cavity generously.
In a separate bowl, combine pork sausage with smoked paprika, garlic powder, onion powder, black pepper, kosher salt, and cayenne. Mix gently with your hands until just combined—don't overwork it.
Divide the seasoned sausage into 24 portions. Press each portion around a filled jalapeño half, fully encasing it like an egg. The sausage should be ¼ inch thick all over.
Preheat your smoker to 275°F with mild smoke wood (oak or hickory work well). Place a drip pan with water on the grates.
Arrange armadillo eggs on the smoker grates, sausage side up, leaving ½ inch between each piece. Smoke for 35–45 minutes until the sausage reaches 160°F internally (check with a meat thermometer in the thickest part).
Remove from smoker when the sausage is cooked through and has taken on a light smoke color. The cheese should be visibly melted inside, and the sausage surface should be lightly browned.
Let cool for 3–5 minutes on a plate before serving. The cheese will set slightly as they cool, making them easier to handle.
Keep the Cheese from Leaking
Use a small spoon to pack the cream cheese mixture firmly into each jalapeño half, and make sure your sausage layer completely seals the filling. If you're worried about blowouts, smoke at 250°F instead of 275°F and add 10–15 minutes to the cook time. Colder sausage cooks more evenly and holds the cheese in better.
FAQ
How do you keep jalapeños from getting too soft when smoking?
Smoke at 250–275°F and pull them when the sausage hits 160°F—don't leave them on the smoker longer. The jalapeño skin should still have some snap to it. If you prefer them firmer, use larger fresh jalapeños, which have thicker walls and hold up better to heat.