Sanding tool and method of making such tool

A method for producing a sanding or finishing tool having a contoured surface with a longitudinal dimension, said contoured surface carrying an abrasive or finishing material, comprising the following steps:

• (a) providing a foaming mold cavity and a profiled body as a separate insert in said foaming mold cavity, said insert having a profiled surface which is complementary to said contoured surface of said tool,
• (b) securing said insert in said mold cavity so that said profiled surface of said insert faces into said mold cavity,
• (c) covering said profiled surface of said insert with an elastic belt carrying an abrasive or finishing material on one belt surface facing said profiled surface of said insert, said elastic belt having a substantial ability to elastically expand in a cross-direction extending across said longitudinal dimension of said contoured surface, and
• (d) introducing into said mold cavity a foamable and curable foam material, closing said mold cavity, foaming and curing said foam material thereby filling said mold cavity so that the pressure resulting from the foaming of the foam material causes said elastic belt to precisely hug said profiled surface of said insert as a result of said elastic belt's ability to elastically expand in said cross-direction, said curing simultaneously bonding said foam material to said elastic belt.