Interesting reading here. I have a powermaster setup on my 85 GN. Any signs and symptoms of it going out? Other than the pedal hitting the floor?
Hearing the motor run too long. Red "brake" light flickering on the dash. Coasting through a red light.
Anyways my conclusions at the moment...
PowerMaster seems risky even if you're a saint about maintaining it with new fluid etc. But if you occasionally discharge the accumulator and then see how long the motor runs to pump it back up it'll give you an idea if things are in good working order and may keep you safe. If the motors runs for an excessive amount of time, don't drive it, something is going bad. Still... too many stories about guys just sitting at a red light and suddenly the warning light pops up and the pedal hits the floor.
Vacuum... only way I would feel safe is with an auxiliary vac pump/reservoir but then that's more $, more plumbing, more wiring, more space to mount parts, more hassle over all. No I've never really heard of a vac system failing but lots of guys chasing down problems with check valves seemingly not working properly etc...
Hydroboost is most attractive to me in terms of sheer stopping power and is 2nd best in terms of reliability. The only thing that could really go wrong is leaking power steering fluid but I've never seen a power steering hose or seal completely blow out and lose a huge amount of fluid. Trickle type leaks if anything. Could probably catch it soon enough to be safe. Conversion kit something like $600 maybe more with lines and fittings.... but the more lines and fittings you add to a system the more spots for it to leak.
Manual brakes. Cheap and reliable. Either convert with old S-10 parts or buy a conversion kit with new master cylinder, pushrod, etc. $200-$300 range total. Extra leg effort required while driving. No PowerMaster motor or accumulator to fail, no tapping into the power steering system and worrying about leaks or seals blowing out, no vacuum check valves to mess with. Downside being no power assist. But no fancy parts to worry about failing, the only things in the equation are your leg and the traditional hydraulic brake system. Maintain fluid, bleed brakes, check routinely for leaks, and don't get a cramp in your leg, and you'll be ok.
I'm leaning towards a manual system with S-10 rear cylinders and a Wilwood front disc brake upgrade to compensate for the loss of power assist.