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Brake dust won't hurt your powdercoating any more than the crap that the road kicks up. Especially if you clean the wheels every now and then.
Change rotors when they need it only. You can measure the thickness with dial calipers; the spec is in the book. They should last through several brake pad changes, assuming you do not get very aggressive pads. Or, you can do it now and know they will be good for many years to come (again, depending on pads).
Don't remove the caliper lines to replace the rotors; just use tie wire to hang the caliper to the side. Trying to remove 26 year old brass fittings will likely result in replacing brake lines, and maybe brake calipers.
The screech sound may simply be brake squeal. Sometimes it can be solved by simply cleaning the caliper and pins and applying silicone grease to the contact areas. If you are hearing squealing because you have worn down to the replacement indicator, or the steel backing on the pad, then you may have scored rotors, and need to replace them regardless of thickness.
Good luck! Brakes can be very very simple, or very very challenging. It all depends on the condition of the calipers.
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