In our prior analytical work concerning a finite element methodology for thermal stress analysis of minimum cooled low heat rejection (LHR) engine cylinder heads, a very fine mesh with strict aspect ratio and element density criteria was used. In this current study, these criteria were relaxed and two other finite element models with different element densities were used to solve the same thermal stress problem. The thermal and stress results of the relaxed models are compared to those of the earlier very fine mesh results. It is the aim of this paper to show in a semi-quantified manner, how mesh density can affect thermal stress solutions in LHR engine heads. Hopefully this will enable other analysts working in this area to make some judgement on mesh density before starting an actual modelling effort, resulting in a savings of time and manpower resources.