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Prep the ingredients: Dice the bell pepper and onion. Slice the andouille sausage into bite-sized rounds. In a skillet over medium heat, cook the ground Italian sausage and diced bacon until fully cooked. Drain excess fat if needed.
Load up the pan: In a large foil pan, combine the baked beans, cooked sausage, bacon, sliced andouille, diced veggies, barbecue sauce, mustard, hot sauce, brown sugar, and BBQ rub.
Mix it all together: Stir until everything is well incorporated and evenly coated in that saucy goodness.
Smoke low and slow: Place the foil pan in a preheated smoker at 225°F. Smoke for 2 hours to allow the flavors to meld and pick up that smoky depth.
Crank the heat to finish: After 2 hours, stir the beans and increase the smoker temperature to 350°F. Continue cooking for another 30–40 minutes, uncovered, to caramelize the top and thicken the sauce.
Serve hot: Serve straight from the foil pan or over rice. These beans hit like a full meal—but they’re also the ultimate side dish.