By the early 1800s, foreign visitors began making regular trips across the ‘āina mauna [mountain lands] and to the summit of Mauna Kea. Based on their accounts, travel in the region through the middle 1800s basically followed the old trails, or cut across new areas.
By the 1850s, the Kingdom of Hawai‘i entered into a program of improving ancient trails and identifying new routes, by which to improve travel between various locations and facilitate commerce. (Maly)
At its May 23, 1849 meeting, the Privy Council of the Kingdom of Hawaiʻi (a private committee of the King’s closest advisors to give confidential advice on affairs of state) sought to “facilitate communication between Kailua, the seat of the local government, and Hilo, the principal port.”
They resolved “that GP Judd and Kinimaka proceed to Kailua, Hawaiʻi, to explore a route from that place to Hilo direct, and make a road, if practicable, by employing the prisoners on that island and if necessary taking the prisoners from this island (Oʻahu) to assist; the government to bear all expenses”. (Privy Council Minutes, Punawaiola)
In planning the road, the words of the Privy Council’s resolution were taken literally, and the route selected ran to the high saddle between Mauna Kea and Mauna Loa on a practically straight line between the terminal points.
What became known as the “Judd Road” (or “Judd Trail”) was constructed between 1849 and 1859; construction began at the government road in Kailua (what is now known as Aliʻi Drive) and traversed through a general corridor between Hualālai and Mauna Loa. (Remnants of perimeter walls can still be seen at Aliʻi Drive.)
“This was the road that Dr. Judd … would have built from Kona in a straight line across the island of Hawaii. It was meant, of course, as a road for horsemen and pack animals. In the generation of Dr. Judd it was a great work, and the manner of its building showed that he meant it to be a monument to him for all time.” (Ford, Mid-Pacific, 1912)
In 1859, when the road had been built about 12-miles from Kailua into the saddle between Hualālai and Mauna Loa, the project was abandoned – a pāhoehoe lava flow from the 11,000 foot-level of Mauna Loa crossed its path. Though incomplete (it never reached its final destination in Hilo,) people did use the Judd Road to get into Kona’s mauka countryside.
This road was not the only attempt of linking East and West Hawaiʻi. The western section of the trail from Waimea to Kalai‘eha (Humu‘ula Sheep Station) had become a ‘cart road’ by 1873; it was only a dirt road through the pasture then and in rainy weather it turned to mud.
There were no automobiles in 1910 and very few in the 1920s, all transportation was by foot, horse, or by wagon, carriage and buggy. In 1920, the cart road left the Waimea/Kona road at Pu’u Nohona‘ohae and went through Waiki’i village to The Saddle.
The cart road initially began a little farther north, however, the manager of Parker Ranch, AW Carter, got the entrance of the road moved so that it passed between Pu‘u Nohona’ohae lki to the north, and Pu‘u Nohona‘ohae Nui to the south. (This is the alignment of the old Saddle Road where it meets the Waimea to Kona ‘Mauka Road.’)
In the saddle area, the old cart road ran directly east from Pōhakuloa to Kalai‘eha (Humu’ula Sheep Station). The eastern section, from Kalai‘eha down to Hilo, remained a trail until World War II, except at the Hilo end. ‘Kaumana Road’ was built (paved) up to the Countly Club Road intersection in Kaumana by the “FTRA” about 1936.
Because there was no road up from Hilo, to get to Kalai‘eha (near Pu‘u Huluhulu and the present Mauna Kea Access Road) and surrounding uses. From Hilo, you had to drive all the way along the Hāmākua Coast (Mamalahoa Highway) around through Waimea and back east through the Saddle. As described by Roy Blackshear, to get to Pu‘u ‘Ō‘ō Ranch (owned by his grandfather):
“The first time I went to Pu‘u ‘Ō‘ō was about 1931. But at that time, of course there was no Saddle Road there, and to get to Pu‘u ‘Ō‘ō Ranch we left Kea‘au before sunrise in the morning, traveled north along the Hāmākua Coast, going through all the valleys and small bridges and so on and finally we reached Waimea and had lunch at Waimea.”
“And then we continued from Waimea along the Mamalahoa Highway. Out to where, I think it was just about where the present Saddle Road takes off. … And of course any car going up at that time would have to carry chains because they did run into mud.”
[They stopped first in Waiki‘i.] “And then we headed on east from there, climbing all the time. So then we continued on and we reach Humu‘ula sheep station. And they put more water in the radiator. And then we started from, there up towards the Keanakolu road …” (Blacksher; Rosendahl)
While ‘Kaumana Road’ was built (paved) up to the Country Club Road intersection in Kaumana by about 1936, from there it was an unpaved wagon road until World War II and above that a horse trail. Above Kaumana, the eastern section (from Kalai‘eha) remained a trail until World War II.
The Saddle Road was built by the Civilian Conservation Corps (CCC) and the US Army Engineer District, Honolulu (USED, now called the US Army Corps of Engineers) during World War II in order to provide an access route in case of Japanese invasion.
Near the top of Kaumana, the army had a camp and barred everyone who didn’t work there from traveling up into the interior of the Island.
Henry Auwae ran the lead bulldozer to clear the road in 1943, coming up from Hilo on the 1881 and 1855 lava flows and choosing a route which kept to no more than a 6% grade. Cinders were then hauled down from Humu‘ula toward Kaumana by the CCC and later the USED, then oiled to make a narrow “gravel” road.
The west section of the road was paved right after the war. The east section of the road was not paved until later, about 1949. At that time the road was moved at several points to cut off some large loops. These old loops still exist, including one north of the road around milepost 9 and another around milepost 22.
Then, starting with an accepted EIS in 1999, what is now known as Daniel K Inouye Highway (renamed on what would have been his 89th birthday) was realigned and widened. Starting in 2007, successive phases of the improved road have been opened up.