This is a less-safe alternative to spending approximately £250 on 51 47 7 380 665 and supporting parts, especially since they are NoS (No Stock) parts that need to be specially ordered from factory.

It's not an exact replica of 51 47 7 380 665 -- the original is 2kg lighter. It's also slightly stiffer as its made out of epoxy resin/fibreglass composite. Having said that, the 18mm MDF provides reasonable stiffness and moisture resistance once sealed properly.

The two parts hinge only using the carpet. Consider installing three piano hinges for more stiffness and loading capacity. If you add them, subtract appropriately from the length of the base element.

The original part is anchored to the car for better crash resilience. You must understand that neither this project part nor the original part pass crash test regulations without the supporting mounts. Do not be tempted to plop the -665 alone and call it a day. The proper, smart BMW engineers have put a lot of thought into this. Do not ignore it!

This project part has not been crash-tested. You must assume and expect it to fail in any and all crash scenarios in the most spectacular and catastrophic way imaginable. I am not an engineer. This is not engineering advice.

It would be sensible to only use it when you are transporting large items requiring a flat floor -- in which case the safety in a crash is already compromised by a large, unsecured mass inside the cabin, where the squishy bits are.

For completeness, to do a fully compliant installation, you would need:

For total of €291.91 or ~£250 ex VAT. Your friendly local dealership will probably charge twice that amount for fitting (merely an opinion; also this list may not be exhaustive, I am not a certified BMW/MINI parts specialist) and add VAT to the prices; so below is the cheapskate alternative.

Files:

  f60_boot_floor_1.pdf

  f60_boot_floor_1.ps

  f60_boot_floor_1.eps

  f60_boot_floor_1.dxf

  f60_boot_floor_1.svg

Pre-requisites:

Method:

From the curved edge, you will need to stretch the fabric as you cover the bottom side as much as it will stretch to go around the curved part. The fabric needs quite a lot of stretch for a good finish but is made to do it. Start at the handle area and work towards the sides in 2-3 sections stretching the fabric towards you as much as you can. It looks impossible at first but it works.

Total cost of materials and services ~£100.

DISCLAIMER: Prices correct at the time of writing. I am not affiliated with the above-linked entities. 
Neither me or my employer endorses the above companies, vendors, or products. I have NOT received any
special pricing or discounts in exchange for mentioning them here. Those links are provided for
reference and your convenience. I do not guarantee accuracy or fitness for a particular purpose of the
linked materials or services. Your experience may vary. This information is provided as-is and without
warranty of any kind. Follow at own risk. This is not engineering advice.
Opinions expressed on this page are mine and not my employer's.

WARNING: MDF is pretty nasty when inhaled in powder form. Wear face and eye protection when working it
especially when cutting/sanding.

Keywords: F60 MINI Countryman flat boot trunk floor DIY