Step 1

Pre-heat oven to 425 degrees F.  This can be done at the beginning of the recipe or just before you are ready to put the stuffed shells in the oven.

Step 2

Start by preparing your chili.  You can use leftover chili or canned chili if you like, you just want to make sure it is pretty thick in consistency.  Heat a large pot over medium heat and olive oil, onion, bell peppers, zucchini and summer squash with a pinch of salt.  Stir together and cook veggies until softened, 7-10 minutes.  Add in the garlic and cook another minute.

Step 3

Add in the beans, canned tomatoes, tomato paste, refried beans and seasonings.  Mix everything together well and let cook for about 5-10 minutes.  Add in a heaping cup of shredded cheese and mix until cheese is melted.  Set chili aside until ready to use.

Step 4

Heat a large pot of water over high heat until boiling.  Add in your extra large shell pasta, along with a little bit of olive oil (to make sure the shells don’t stick together).  Cook until shells are aldente, about 10-12 minutes.  Drain pasta and rinse with cold water, to stop the cooking process.  Allow shells to cool long enough that you can handle them.  I like to lay them out on a clean kitchen towel because that helps ensure they are not sticking together and it allows for me to be able to open them up.

Step 5

Add about 1/2 cup of chili sauce to the bottom of a large baking dish and spread around in an even layer.  Use a spoon to fill each shell with the chili mixture, you want a couple of tablespoons in each one.  Place the filled shells into the baking dish in a single layer, you can pack them in as lightly as you like.

Step 6

Top each shell with a little spoonful of chili sauce and then top all the shells with about 3/4 cup of shredded cheese, or more if desired.  Place the shells in the oven and bake until cheese is completely melted, 20-25 minutes.  You can also cover with foil for the first 15 minutes or so and then remove it to make sure the cheese gets completely melted.  Top with your favorite chili toppings and enjoy!