Need to build a permanently connected battery charger for a 36V 7Ah lead acid battery pack. On/off control on the 220VAC side. Considering utilizing a LM317 regulator with a Zener/diode combination on the Adj leg to get 43.5 volt output with 1A max. Will this work or am I going to release the smoke contained in the regulator?

 

You might be able to build a 1A charger using a LM317HV version. What is the input voltage source?

 

You might be able to build a 1A charger using a LM317HV version. What is the input voltage source?

48V trafo, bridge rect and filter caps

 

Just be very careful not to exceed input voltage max for the part.

 

use an LM317HV, it will take 60volts input, at 1.5Amps output

http://www.datasheetcatalog.org/datasheet/nationalsemiconductor/DS009062.PDF

 

I get 60 volts DC from a 36V toroid already.

I would recommend a 12V electronic transformer, and a step-up converter.
There are some cheap one's ready made, but only max. 35V
you have to "tune" it a bit but easily possible.

All these linear regulators are messy. For the money the heatsink costs, you can already buy a 12V / 35V converter. For a few volts more, you need to insert one small resistor.