I would avoid Innovision's PowerBoard because when I ran the installer I got a blank page and the support forum was no help. I prefer phpBB to vBulletin as far as off-the-shelf forum programs go because the profile and private message interfaces are more coherent from the end user's perspective. However, phpBB has a bug that causes the database to become corrupted if a thread reaches 4,000 posts - usually not a problem with small low-traffic sites.
That said, I write my own PHP message boards because it's easier to extend my own code than someone else's and because I like to integrate the board's "look and feel" with the Web site's overall layout better than can be achieved by simply matching the color scheme with stylesheets.
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